SAM Fuse Holder

Thanks to forum member Paul.art for sending me this fuse holder.

Extra Fuses Using SAM Fuse Holders

The SAM unit has nine extra fuse places down the side, smart obviously put them there for their own usage but as most cars rarely use more than two of them, let’s take advantage.

What Amperage Are They?

That’s the best bit, it is what ever you want it to be. Any standard size automotive fuse will fit into the holders which are then clipped into the SAM unit.

What Control Do I Have?

You have two options for the power to the fuse:

Constant Live
Switched Live

The constant live is always on and the switched live comes on when the ignition key is turned to position 1.

How Do I Select It?

The four fuse spaces nearest to you are switched live.
The five fuse spaces furthest from you are permanently live.

They are labeled to the side of the connections.

R1 – Switched
R2 – Switched
R3 – Switched
R4 – Switched
R5 – Permanent
R6 – Permanent
R7 – Permanent
R8 – Permanent
R9 – Permanent

The Fuse Holders

The fuse holders used to come in several colours:

The colour you use depends on the application. Some will only fit in the constant live locations and vice versa. The only difference apart from the colour is the location of a small plastic tab to stop it sliding in the wrong position on the SAM unit.

Here we can see the holder with a fuse removed.

The fuse pushes into the holder where it is held in with a clip.

The clip can then be inserted into the SAM unit after being wired up.

These can be bought directly from smart.

The part numbers are:

Permanent Live

Brown – A 211 545 09 01
Brown – A 004 545 61 01 (Thanks Jonny C)
Orange – A 004 545 64 01 (Thanks Soran)
Orange – A 211 545 12 01
Bordeaux – A 004 545 62 01
Pink – A 004 545 63 01

Switched Live

Black  – A 211 545 05 01
Black – A 004 545 61 01 (Thanks Jonny C)
Natural – A 004 545 58 01
Green – A 004 545 60 01
Midnight blue – A 004 545 59 01

Will Not Fit Without Modifications

Turquoise – A 004 545 65 01
Light blue – A 004 545 66 01
Grey – A 004 545 67 01
Red – A 004 545 68 01
Yellow – A 004 545 69 01
Violet – A 004 545 70 01

These don’t fit straight to the smart SAM unit but click here to see how to modify them.

Thanks to James and David K for the part numbers and colours.

Metal Terminal

Clip in terminal – 004 545 52 26 (0.5mm to 1mm square cables) (below left)
Clip in terminal – 011 545 84 26 (1mm to 2.5mm square cables) (below right)

The terminals are the clip in metal connections that fit inside the fuse holders.
Thanks to David K for the cable size info.

Buying These Items

They originally retailed for about £11 each but they have come down to £1.50 Remember that you need to purchase the terminal as well which are about £1.

These can be bought directly from Smart using the above part numbers.

Fitment Types

Mercedes have fitment A, B, C and D. This (of course) makes no sense to the untrained eye.

A = Switched live
B= Permanent live
C= Doesn’t fit unless modified
D= Doesn’t fit unless modified

They only fit in particular slots on the SAM unit due to the position of the raised section in the centre.

A= Left
B= Centre Left
C= Centre Right
D= Right

The easy way to remember this is with the word SPAM. Starting with the tab on the left and working across.
S= Switched
P= Permanent
A= Adapt
M= Modify

Adapting Permanent To Live (And Vice Versa)

What happens if (like had happened to me) you buy permanent live but need switched live fuse holders? Needed permanent but needed switched? Or had some non fitting types and needed them to fit?

A switched live fuse holder will not push into a permanent fuse slot and the same goes for the other way around. Not to worry though as it’s very simple to modify.

Here is a permanent fuse holder, note the small line of plastic down the inside.

Use a knife/file/sandpaper/teeth to remove the tab as shown below. Permanent live fuse holders have the tab centre left, switched are near the left edge.

With that plastic tab taken out the fuse holder will fit in all locations and work fine.

In fact, I found the adapted ones to be more secure.

Constructing A Fuse Holder

Get a suitable gauge wire, strip back about 6mm and push it into the crimp. I have never liked crimping stuff as you never get a really good join unless you use the right equipment. As they cost a lot of money and no one will have one, it’s easier to solder.

Flux the bare wire end and the contact and apply heat and solder until it runs around the wire.

Allow to cool before sliding it into the back of the fuse holder until you hear a click.

Push the locking tab in place to double lock the contact in position.

Insert the fuse of the rating you require.

You are ready to join it to what ever you are powering and plug it into the SAM.

Remember that these will output 12 volts so check what you are powering.

Amperage Limits

Switched

The 4x switched live connections at R1, R2, R3 and R4 are switched by a 40 amp relay. However, this relay also switches power to a lot of other things.

For example, on the Roadster, this relay also switches power to the: airbag controller, ESP controller, electric mirrors, soft top switch, CD player, speedo, 12v power socket.

It is not recommended that you connect more than a total of 20 amps to R1, R2, R3 and R4.

Permanent

You obviously aren’t restricted by a relay on the permanent live rail, however, you can be limited by the PCB track, solder joints and fuse connections. For permanent live positions R5, R6, R7, R8 and R9 I would recommend a maximum of 40 amps per connection. I prefer a direct battery connection for anything over 20 amps though.