POWR SPEED TecAppGuide 2 Sizing Guidelines 2021 Final 1
POWR SPEED TecAppGuide 2 Sizing Guidelines 2021 Final 1
SECTION 4.0
POWR-SPEED ® Fuses
Sizing Guidelines
TABLE OF CONTENTS
INTRODUCTION................................................................................................................................................. 2
4.1 Rated Voltage............................................................................................................................................. 2
4.1.1 Effect of Operating Frequency (Ef )...................................................................................................... 2
4.1.2 Effect of Time Constant (Efc)............................................................................................................. .3
4.1.3 Effect of Regenerative Loads (Ereg)..................................................................................................... 3
4.1.4 Effect of Complying Fuse Standard.................................................................................................... 3
4.2 Rated Current............................................................................................................................................. 4
4.2.1 Sizing of the High-Speed Fuse Rated Current..................................................................................... 4
4.3 Interrupting Rating.................................................................................................................................... 16
4.4 Total Clearing I2 t Value (Withstand Energy)............................................................................................... 16
4.5 Peak Arc-Voltage...................................................................................................................................... 16
The proper selection of high-speed fuses involves greater understanding and consideration of its product
specifications such as rated voltage, rated current, interrupting rating, and melting and total clearing l2t ratings,
and then sizing them appropriately to various application conditions.
This document, which is excerpted from the POWR-SPEED Fuses Application Guide, discusses the general
industrial guidelines for sizing high-speed fuse specifications based on these influencing application conditions.
Download complete, 52-page POWR-SPEED Fuses Application Guide at Littelfuse.com/powr-speed-application-
guide for an in-depth look at high-speed fuse protection.
En ≥ E
Ef
Example:
Application Voltage Rating (E) = 480 V ac
Application Frequency = 30 Hz
Frequency Correction Factor (Ef) = 0.9
En ≥ E ≥
480 V ac
Minimum Fuse AC Voltage ≥ 533 V ac
Ef 0.9
And thus, the recommendation would be to use a 550 V ac or 600 V ac rated fuse.
E
Minimum high-speed fuse rated voltage: En =
0.9
So in summary, the rated voltage of a fuse is determined using the formula:
E x Ereg
En =
Ef
For North American style fuses used in IEC applications, the rated ac voltage of a fuse is determined by:
E x Ereg
En =
0.9 xEf
Where:
E = Application voltage rating
Ereg = Regenerative load safety factor
Ef = Frequency correction factor
◄
◄
◄
PEAK
RMS
AVERAGE
◄
◄
◄
Figure 25. Relationship between ac rms current and dc average current for a single-phase unfiltered full-wave rectifier circuit.
Where,
IPEAK = Peak Current
IAVG = Dc Average (Output) Current
IRMS = Ac RMS Current
Single Phase – Half Wave Rectifier Single Phase – Full Wave Rectifier (Bridge)
A ▶
▶
A I1
◄ I1
◄ A
I2
LOAD
LOAD
◄ A
I3
◄
▶
I1 = 1.57A I1 = 1.11A I 2 = 0.79A I 3 = 1.11A
Three Phase – Half Wave Rectifier Three Phase – Full Wave Rectifier
A ▶ A
▶
I1
I2
I3
▶ A A A
I2
I1 LOAD
▶ LOAD
▶
▶
▶
Single Phase – Full Waver Rectifier (Center Tap) Six Phase – Single Wave Rectifier
◄ A ▶
A A
I2 I2
▶ I1
▶
LOAD
◄ A
I1
LOAD
Figure 26. Typical rectifier circuits and locations of high-speed fuses in the circuitry
When the current through the fuse is constant and continues for one hour or more, then the calculated normal
load current is similar to the ac rms current or the dc steady state current per the illustrations above.
However, for applications involving varying load current, especially when subjected to inrush current or cyclic
current (regular-repeating identical current cycles), the normal load current through the fuse is obtained by
calculating the rms current of one duty cycle, known as adjusted normal load current.
Figure 27 is a representation of a typical varying load cycle. The adjusted normal load current for this varying load
cycles is provided by the formula,
◄
◄
l1
l2
◄
◄
◄ ◄
◄ t1 ◄ t2
◄
◄ T
Figure 27. Varying load current (cyclic current)
Where,
I1, I 2...In: Varying RMS load currents (amperes)
t1, t2...tn: Corresponding current cycle duration (seconds)
T: Total duration of one varying load current cycle
(Including any OFF period)
Example:
Determine the adjusted normal load current for the cyclic current shown in Figure 28.
80
75
70
60
50
◄
◄ ◄
6 26
◄ 13
◄
◄
40
◄
AMPERES
30
End of Cycle
20 38
10
◄
◄
0
0 10 20 30 40 50
Figure 28. A cyclic current.
Where,
I1: 75A
t1: 6 Seconds
I 2: 38A
t2: 26 Seconds
I3: 0A
t3: 13 Seconds
Total Time (T): 45 Seconds
40A
For irregular current cycles, the adjusted load current must be calculated for a period of one hour, during which
the largest effective surge current would occur.
Depending on the magnitude and duration of the surge current, the calculated adjusted normal load current (IAL)
may be substantially less than the surges in the system.
Other common scenarios observed in power semiconductor applications would involve having multiple power
semiconductor devices connected in parallel (as shown in Figure 29). In this scenario called a multi-parallel connection,
each device is protected by an individual high-speed fuse in each arm/leg of the power conversion circuit.
⦧
⦧
⦧
⦧
⦧
⦧
⦧
⦧
⦧
⦧
⦧
⦧
▲▲▲▲ ▲ ▲ ▲▲ ▲ ▲▲▲
LOAD
b
c
⦧
⦧
⦧
⦧
⦧
⦧
⦧
⦧
⦧
⦧
⦧
⦧
▲ ▲▲ ▲ ▲ ▲ ▲▲ ▲ ▲▲▲
In such situations, the load current through each arm/leg is shared between all parallel paths. Though load current
sharing is typically not equal, as up to 20% of uneven sharing is allowed. Continuous operation of this multi-
parallel circuitry with one less parallel path (due to fuse operation on an internal fault) is also possible. Thus, when
determining the load current through the fuse in such multi-parallel circuits, both these conditions should be
considered.
The normal load current (IAL) through each fuse in a multi-parallel connection circuitry is determined by:
Where,
IAL(Leg) = Total rms current in each arm/leg
N = Total number of parallel path in each arm/leg
S = Load current sharing factor (0 %-20 %)
The rated current of the high-speed fuse being selected can be determined by applying re-rating factors
(computed in Step 2 below) to the normal load current (IAL) determined from this section.
Where,
IAL = Adjusted normal full-load current
IN = Rated current of high-speed fuse for the application
FAT = Ambient temperature correction factor
FFC = Forced cooling correction factor
F WR = Wiring connection factor
FSS = Switching correction factor
FAL = Altitude correction factor
2a: Ambient Temperature Fuses are affected by the air temperature immediately surrounding it (ambient
temperature) during its operation. Typically, high-speed fuses are tested at standard test conditions of 20
°C ± 5 °C and can be applied at a wide operation temperature range of -50 °C to +125 °C. When fuses
are operated at ambient temperatures outside their standard testing range, the appropriate ambient
temperature correction factor needs to be computed and factored to properly select the fuse rating. The
ambient temperature correction factor (FAT ) is determined by the formula
Where,
Ta = Application ambient temperature
Tstd = Standard testing ambient temperature
Example:
Determine the ambient temperature correction factor for a fuse installed at a 55 °C ambient temperature
condition?
Per formula, it is calculated to be:
FAT = 0.84
2b: Forced Cooling: Due to their switching properties, power semiconductor devices typically produce
large amounts of heat during normal operating conditions. When the heat produced exceeds their safe
operating temperature limits, the devices will become inoperable.
Forced air cooling and liquid cooling are the two heat sinking methods commonly practiced in such
applications. Fuses that are used to protect such devices are also subjected to such heat sinking methods
and can directly affect (increase) the current carrying capacity of the high-speed fuse.
The curve shown in Figure 30 determines the Forced (Air) Correction Factor (FFC) to be used when sizing
the rated current of a high-speed fuse.
1.25
1.20
1.15
1.10
1.05
1.00
0.95
0.90
0
1
2
3
4
5
6
7
8
Air
Velocity
(m/sec)
Example:
Determine the forced air cooling correction factor for a fuse installed at an application with an air velocity
of 4 m/sec.
Per the forced air correction curve:
An average current density and reference values (100 %)
For an air velocity of 4m/sec, FFC = 1.20
For applications with a liquid cooled bus-bar system (which may be used along with forced air cooling),
the forced cooling correction factor of FFC = 1.25 can be considered when sizing a high-speed fuse’s
rated current.
2c: Conductor Size (Wiring Connection Factor): High-speed fuses are connected to a system by means
of copper conductors in the form of cable or bus-bar termination. The main purpose of the termination
is to conduct power, but they also serve as a heat sinking device to remove heat from the fuse terminals
and allowing it to operate efficiently.
The cross-section size of the conductor significantly impacts the current carrying capacity of a high-
speed fuse. The rated current of a high-speed fuse is determined based on testing with recommended
conductor sizes outlined in international standards. When applying these fuses in the field, any reduction
in conductor size would require appropriate de-rating of the fuse rated current. In other words, fuse
current ratings should be determined based on the cross-section size of the conductor.
Per IEC 60269-4 Standard Section 8.3.1, the current density of the copper conductor used shall be
between 1.0 A/mm2 (minimum) to 1.6 A/mm2 (Maximum) and vary with the rated current of the fuse.
For ease of calculation, 1.3 A/mm2 is considered as the reference value (100 %) for the conductor sizes.
Based on this reference value and the application conductor size, the wiring correction factor (F WR) for the
application is determined from the curve showing in Figure 31 and factored in accordingly while sizing
the rated current of high-speed fuses.
Wiring
Connec+on
Factor
Curve
(FWR)
1.10
Wiring
Connec+on
Factor
(FWR)
Wiring Connection Factor (FWR)
1.00
0.90
0.80
0.70
0.60
0.50
50%
55%
60%
65%
70%
75%
80%
85%
90%
95%
100%
Current
Conductor Size Density
(100%
(100%
=
1.3A/mm
= 1.3A/mm 2
) 2)
Example:
Determine the wiring connection factor for an application with a 400 A load current using copper
conductor with a cross-section of 185 mm2.
Load current: 400 A
Conductor size used in application: 185 mm2
Copper current density per IEC standard: 1.3 A/mm2
Based on the IEC recommended conductor size determined above, the application conductor size used is
about 60 % of the recommended size.
Applying the 60 % value determined in the wiring connection factor curve, the wiring connection factor
for the application is, F WR = 0.92
2d: Frequency: High-speed fuses have one or more fusible elements connected in a parallel configuration
within their fuse body. When these fuses are subjected to high frequencies, and due to the
electromagnetic property of AC power, the flow of current through the fuse is constrained to the outer
layers of the fusible element, known as skin and proximity effect. This phenomenon causes unbalanced
sharing of current between fusible elements resulting in increased heat, which significantly reduces the
current carrying capacity of a fuse and could result in premature operation of a fuse.
Applications with a frequency above 10 kHz are considered as very high frequency applications and
require increased attention when sizing high-speed fuses. Consult Littelfuse Technical Services for such
applications.
The curve shown in Figure 32 determines the frequency correction factor (FHZ ) to take into consideration
when sizing the high-speed fuse rated current.
1.00
0.90
0.80
0.70
0.60
0.50
10
100
1000
10000
Frequency
(Hz)
Example:
Determine the frequency correction factor for an application with application frequency of 500 Hz.
Application frequency: 500 HZ
From the frequency correction factor curve shown in Figure 32, the corresponding frequency correction
factor for the application is FHZ = 0.96
2e: Switching and Surges: In general, all electrical equipment is subjected to start-stop operations. The
frequency of start (ON) and stop (OFF) operation and the associated surge in current during switching
determines the aging effect on high-speed fuses.
An ON-OFF operation induces heating and cooling effects on fuse elements. The higher the number of
switching operations, the greater the impact on the fuse current carrying capacity over a period of time.
The switching correction factor table below provides the recommended switching de-rating factors (FSS)
to be considered for any frequent switching applications.
2f: Altitude: Increase in altitude above 2000 m mean sea level (MSL) causes reduction in heat dissipation
due to convection and radiation within fuse elements.
A general industry practice of 0.5 % de-rating in component current rating for every 100 m above 2000
m mean sea level should be applied while calculating the high-speed fuse rated current.
Altitude correction factor is given by the term FAL = (1-((h-2000)/100)*0.005) where 'h' is the application
altitude.
Example
What is the altitude correction factor to be used for installation applied at 3500m above sea level?
Application Altitude (h): 3500 m
Altitude Correction Factor Formula:
FAL = (1-((h-2000)/100)*0.005)
FAL = (1-((3500-2000)/100)*0.005)
FAL = (1-(0.075))
FAL = 0.925
Altitude Correction Factor FAL = 0.925
Rated Current of the High-Speed Fuse: In summary, the rated current of a high-speed fuse can be
determined using the following formula:
Where,
IAL = Adjusted normal full-load current
IN = Rated current of high-speed fuse for the application
FAT = Ambient temperature correction factor
FFC = Forced cooling correction factor
FWR = Wiring connection factor
FSS = Switching correction factor
FAL = Altitude correction factor
IAL
IN =
FAT * FFC * FWR * FHZ * FSS * FAL
Example:
Determine the suitable Littelfuse POWR-SPEED North American round body fuse for a rectifier
application with the following system details:
Ac system voltage = 600 V
Frequency = 60 Hz
Ambient temperature (Ta) = 65 °C
Forced air cooling = 3 m/s
Load current = 100 A
Available short-circuit fault current = 35 kA
Load condition = 15 stops per day
Overload condition = 200 % for 10 sec for every 3 minutes
Thyristor l2t withstand rating = 20,000 A 2s
Load Current:
I1I12t2 1t+
1 +I2I2 t2t2
22
IAL =
T
= (1002 ✱ 180) + (200 2 ✱ 10)
190
IAL = 107.6
Ambient Temperature Correction Factor:
125 — 65
FAT =
125 — 25
FAT = 0.775
107.6
IN =
0.775 ✱ 1.15 ✱ 0.8
107.6
IN =
0.713
IN = 150.9 ˜ 150A
Upon calculating the rated current including all of the factors involved, POWR-SPEED fuse part number
L70QS150.V rated for 150 A, 700 V ac/dc, and 200 kA I.R. could be considered for this application.
This fuse has a total clearing l2t value of 13,650 A 2s at 700 V ac which, is less than the thyristor device
withstand rating of 20,000 A 2s, and meets the voltage and current rating requirements of the application
and thus can be recommended.
Interrupting rating of the fuse selected should be greater than the application's available fault current to provide
adequate protection.
Total clearing I2t value < Semiconductor Device Fusing I2t Value
Total clearing I2t value of the fuse should be less than the semiconductor device's withstand rating or fusing I2t
value (expressed in A 2s).
Peak arc-voltage calculated should be less than the peak inverse voltage (PIV) of the semiconductor device used.
DISCLAIMER
The purpose of this Technical Applications Guide is to promote a better understanding of high-speed fuses,
power semiconductor devices and their common application details within circuit design. These high-speed fuses
being considered are current sensitive devices designed to serve as the intentional weak link in the electrical
circuit. Their function is to provide protection of power semiconductor components, or of complete circuits, by
reliably operating under current overload conditions.
Application guidelines and product data mentioned in this guide is intended for technical reference only.
Fuse parameters and application concepts should be well understood to properly select a fuse for a given
application. Application testing is strongly recommended and should be used to verify fuse performance in the
circuit/application.
Littelfuse products are not designed for, and shall not be used for, any purpose (including, without limitation,
automotive, military, aerospace, medical, life-saving, life-sustaining or nuclear facility applications, devices
intended for surgical implant into the body, or any other application in which the failure or lack of desired
operation of the product may result in personal injury, death, or property damage) other than those expressly
set forth in applicable Littelfuse product documentation. Warranties granted by Littelfuse shall be deemed void
for products used for any purpose not expressly set forth in applicable Littelfuse documentation. Littelfuse shall
not be liable for any claims or damages arising out of products used in applications not expressly intended by
Littelfuse as set forth in applicable Littelfuse documentation. The sale and use of Littelfuse products is subject to
Littelfuse Terms and Conditions of Sale, unless otherwise agreed by Littelfuse.
For more information visit Littelfuse.com/Product-Disclaimer
Littelfuse reserves the right to make changes in product design, processes, manufacturing location and literature
information without notice. For additional questions, contact Littelfuse Technical Services Group at
1-800-TEC-FUSE or [email protected].