Fuse

3- Fuse
3-1 Introduction
• Fuse is the most common and widely used protective device in
electrical circuits. There is quite a lot of low voltage distribution circuits
are protected with fuses. Further fuses form a major backup protection
in medium-voltage and high-voltage distribution up-to 13.8 kV, where
switches and contactors with limited short-circuit capacities are used.
• Historically the open tin-foil (rewireable) fuse is the first or the earliest
type of fuse introduced to protect low voltage distribution circuits
against overload or faults.
• This type of fuse was often considered as casual device until not so
long ago. It sometimes came in for a lot of misuse. If it blew constantly,
then the new fuse was just increased until it stayed in permanently.
Greater precision only became possible with the introduction of the
Cartridge fuse.
3.2 Rewireable type
As the name indicates the fuse can be replaced or ‘rewired’ once it fails.
Fusible wire used to be contained in an asbestos tube to prevent splashing
of volatile metal.

Disadvantages
1. Open to misuse due to incorrect rating of replacement elements, hence
giving incorrect protection.
2. Deterioration of element as it is open to the atmosphere.

Figure 3.1 Rewireable type Fuse

 3.3 High Rupturing Capacity Fuses (or Cartridge type )
It is constructed from:
1. A ceramic barrel inclosing the fusing element with metal-end caps and
filled with quartz powder.
2. Fusing Element made of silver strips specially shaped (see Figure 3.1).

Figure 3.2 Sectional view of a typical class – HRC Fuse (Cartridge Fuse)
 Advantages of High Rupturing Capacity Fuses
Correct rating and characteristic fuses are always fitted to a circuit and are not
open to misuse as rewireable type.
1. Arc and fault energy contained within insulating tube prevents damage.
2. Normally sealed therefore not affected by atmosphere hence gives more
stable characteristic and reliable grading.
3. Can operate considerably faster, suitable for higher short-circuit duty:
− Cartridge type can handle 100 000 A
− Semi-open type can handle 4000 A.

High Voltage Fuses

Low Voltage Fuses
 3.4 Operating characteristics
All fuses irrespective of the type have inverse characteristic as shown in graph
that follows. Inverse means that they can withstand their nominal current rating
almost indefinitely but as the currents increases their withstanding time starts
decreasing making them ‘blow’. The blowing time decreases as the flowing
currents increase. The thermal characteristic or withstand capacity of a fuse is
indicated in terms of ‘I2t’ where I is the current and t is the withstand time (see
Figure 3.2). The prospective current is the Irms that would flow on the making of a
circuit when the circuit is equipped for insertion of a fuse but that the fuse is
replaced with a solid link. The curves are very important when determining the
application of fuses as they allow the correct ratings to be chosen to give grading.

Fuse standard
This standard lays down definite limits of:
(a) Temperature rise.
(b) Fusing factor = minimum fusing current/current rating = 1.4
(c) Breaking capacity.
(d) Rating-voltage of system.
These are all dependent on one another. For example, a cool working fuse may
be obtained at the expense of breaking capacity. Alternatively, too low a fusing
factor may result in too high a temperature, therefore too close protection and
possibilities of blowing are more.
Figure 3.2 Inverse Characteristic of fuse
 3.6 Energy ‘let through’
Fuses operate very quickly that they can cut-off fault current long before it reaches its
first peak (see Figure 3.3). The operation time of fuse is smaller than that of CB
because the metal fuse melting process is faster than the break mechanisms of the
CB contacts.
If a fuse cuts off in the first quarter cycle, then the power let-through is I²t. By
comparison, circuit breakers can clear faults in any time up to 10 cycles and in this
case the power let-through is the summation of I2 for 10 cycles. The energy released
at the fault by CB is therefore large compared with that let through by a fuse. Damage
is therefore extensive. In addition, all apparatus carrying this fault current
(transformers, etc.) is subjected to high magnetic forces proportional to the fault
current squared (IF2)!

Figure 3.3 Energy ‘let through’ of HRC fuse-link

 3.7 Application of fuses “Selection of fuses”
The fuses blow when I²t reaches its fusing limit. This property limits the use of
fuses in circuits where the inrush currents are quite high and flow for relatively
long time. Motors, as example, draw more than six times their full load current
for a short time ranging from milliseconds to few seconds depending on the
capacity. Hence, it is not possible to use fuses as overload protection in such
circuits. Accordingly, the fuses are mostly used as short-circuit protection rather
than as overload protection in such circuits. The fuses can be used as either for
overload and short-circuit protection as below:

1. Circuits where the load does not vary much above normal value during
switching on and operating conditions. Resistive circuits like lamps show
such characteristics. Hence, it is possible to use fuses as overload
protection in such circuits. They also protect against short circuits.

2. Circuits where loads vary considerably compared to the normal rating e.g.,
direct-on-line motors, cranes, rolling mills, welding set, etc. In these cases,
fuses are used to provide short-circuit protection only.
Fuse selection depends on a number of factors:
• Maximum fault kVA of circuit to be protected
• Voltage of circuit.
The following factors need to be considered when fuse is to be selected for an
application.
1. Full load current of circuit: the cut-off current increases as the rating
increases. Hence if a higher-rated fuse is used it may take longer time to
blow under short circuits which may affect the system depending upon the
value and duration. Hence, greater benefit is derived from use of correct or
nearest rating cartridge fuses compared to the circuit rating.
2. Degree of overcurrent protection required: It is necessary to consider
slightly higher rating for the fuses compared to maximum normal current
expected in a system. This factor is called the fusing factor and can be
anywhere between 1.25 and 1.6 times the normal rating.
3. Level of overcurrent required to be carried for a short time without
blowing or deteriorating e.g., motor starting currents. This point is
important for motor circuits. Fuses must be able to carry starting surge
without blowing or deteriorating.
4. Whether fuses are required to operate or grade in conjunction with
other protective apparatus. This factor is necessary to ensure that only
faulty circuits are isolated without disturbing the healthy circuits.
Depending on the configuration used, coordination must be achieved between:
• Fuses and fuses
• Fuses and relays, etc.
There is no general rule laid down for the application of fuses and each problem
must be considered on its own merits.
3.8 General Rules
3.8.1 Short-circuit protection
Transformers, fluorescent lighting circuits
Transient switching surges – take next highest rating above full-load
current.

Capacitor circuits
Select fuse rating of 25% or greater than the full-load rating of the circuit
to allow for the extra heating by capacitance effect.

Motor circuits
Starting current surge normally lasts for 20 s. Squirrel cage induction
motors:
• Direct-on-line takes about 7 times full-load current
• 75% tap auto-transformer takes about 4 times full-load current
• 60% tap auto-transformer takes about 2.5 times full-load current
• Star/delta starting takes about 2.5 times full-load current.
3.8.2 Overload protection
Recommend 2:1 ratio to give satisfactory discrimination.