Name of Laboratory : Electrical Safety

Lab Subject Code : EEE1021

Name of School : SELECT

Exp. 1 - Study of Fuses and Types of Fuses

Aim:

To study, compare and analyze the role of fuse and various types based on its application

To compute the fuse ratings of re-wirable fuses and carry out a suitable experiment to determine
the blow-out of the fuse

Fuses:

Fuse is a device which is used to protect circuits from over current, overload and ensures the
protection of the circuit. There are many types of fuses available in the market, but the function of
all these fuses is same. Fuse consists of a low resistance metallic wire enclosed in a non-
combustible material. Whenever a short circuit, over current or mismatched load connection
occurs, then the thin wire inside the fuse melts because of the heat generated by the heavy current
flowing through it. Therefore, it disconnects the power supply from the connected system. In
normal operation of the circuit, fuse wire is just a very low resistance component and does not
affect the normal operation of the system connected to the power supply.

Types of Fuses:

There are different types of fuses available in the market and they can be categories on the basis of
different aspects. Fuses are used in AC as well as DC circuits.

Page | 4
 Name of Laboratory : Electrical Safety
Lab Subject Code : EEE1021
Name of School : SELECT

Different Types of Fuses:

Fuses can be divided into two main categories according to the type of input supply voltage.

1. AC fuses
2. DC fuses

AC and DC Fuses

There is a little difference between AC and DC fuses used in AC and DC systems.

In a DC system, when the metallic wire melts because of the heat generated by the over current,
then an arc is produced and it is very difficult to extinguish this arc because of constant DC value. In
order to minimize the fuse arcing, DC fuse are slightly bigger than an AC fuse which increase the
distance between the electrodes to reduce the arc in the fuse. On the other hand, i.e. in the AC
system, voltage with 60Hz or 50Hz frequency changes it amplitude from zero to 60 times every
second, so arc can be extinct easily as compared to DC. Therefore, AC fuses are little bit small in
sizes as compared to DC fuses.
Fuses can also be categorized based on one time or multiple operations.
1) One time use only Fuse 2) Resettable Fuses

One time use only Fuse

One time use fuses contain a metallic wire, which burns out, when an over current, over load or
mismatched load connect event occur, user has to manually replace these fuses, switch fuses are
cheap and widely used in almost all the electronics and electrical systems.
Such types of fuses can be categories on the following basis.

Current carrying Capacity of Fuse

Breaking capacity

I2t value of Fuse

Response Characteristic
Rated voltage of Fuse
Packaging Size

Page | 5
Name of Laboratory : Electrical Safety
Lab Subject Code : EEE1021
Name of School : SELECT

Other Types of Fuses

Cartridge fuses
Cartridge fuses are used to protect electrical appliances such as motors air-conditions, refrigerator,
pumps etc, where high voltage rating and currents required. They are available up to 600A and 600V
AC & widely used in industries, commercial and domestic distribution panels.
There are two types of Cartridge fuses. 1. General purpose fuse with no time delay and 2. Heavy-
duty cartridge fuses with time delay. Both are available in 250V AC to 600V AC and its rating can be
found on the end cap or knife blade.

Blade Type fuses:

This type of fuses (also known as spade or plug-in fuses) comes in plastic body and two metal caps
to fit in the socket. Mostly, they used in automobiles for wiring and short circuit protection. Blade
Type fuses: used in automobiles

Page | 6
Name of Laboratory : Electrical Safety
Lab Subject Code : EEE1021
Name of School : SELECT

Types of fuses include the simple re-wirable fuses, Resettable (SMD) fuses, Axial fuses, Thermal
fuses, HRC (High Rupturing Capacity), High Voltage fuses etc

Resettable Fuses |Image Credit: Wikipedia

Resettable Fuses:

Resettable fuse is a device, which can be used as multiple times without replacing it. They open the
circuit, when an over current event occurs and after some specific time they connect the circuit
again. Polymeric positive temperature coefficient device (PPTC, commonly known as a resettable
fuse, poly-switch or poly-fuse) is a passive electronic component used to protect against short
current faults in electronic circuits.
Application of such fuses is overcome where manually replacing of fuses is difficult or almost
impossible, e.g. fuse in the nuclear system or in aerospace system.

Resettable Fuses |Image Credit: Wikipedia

Page | 7
Name of Laboratory : Electrical Safety
Lab Subject Code : EEE1021
Name of School : SELECT

HRC Fuse (High Rupturing Capacity Fuse) and its Types:

This type of fuse contains a fuse wire in it, which carries the short circuit current safely for a given
time period. During this period, if fault is removed, then it does not blow off otherwise it will melt
and remove the circuit from electrical supply hence, the circuit remains safe.

The common material, which is used to make an HRC fuse is glass, though this aspect is not always
the case. Other chemical compounds are also used in HRC fuse manufacturing and construction
based on different factors. Its external enclosure is made fully airtight in order to avoid the effect of
atmosphere on the fuse materials. The major objection on HRC fuse is low and uncertain breaking
capacity of semi-enclosed fuse.

Fig: HRC Fuses |Image Credit: www.electricaltechnology.org

Construction and Operations of HRC fuse:

HRC Fuse consists of highly heat resistant material (such as ceramic) body having metal-end caps,
which is welded by silver current carrying element. The fuse body internal space is completely
packed with a filling powder. The material, which has filled the inside space, may be plaster of
Plaster of Paris, quartz, chalk, marble, dust and cooling mediums etc. Thus, it carries normal current
without overheating. The heat being produced vaporizes the silver melted element. Chemical
reaction taking place between silver vapor and filling powder results in high resistance substance,
which helps in quenching the arc in fuse.

Page | 8
Name of Laboratory : Electrical Safety
Lab Subject Code : EEE1021
Name of School : SELECT

Fig: HRC Fuse Construction and Operation|Image Credit: www.electricaltechnology.org

Types of HRC Fuses:

NH Fuse
Din type
Blade contact
NH Type H.R.C Fuses:
NH fuse provides overload and short circuit protection for low and medium voltage. They provide
backup protection to motor starters and other equipment against short circuit and overload. They
are light in weight with compact dimension.

Din Type HRC Fuses:

Din type fuses are available in wide range of rated currents. DIN fuse are used for different
purposes with their characteristic at different temperature condition. They types of fuses
are available for different voltages level and can be used in transformer protection even

Page | 9
Name of Laboratory : Electrical Safety
Lab Subject Code : EEE1021
Name of School : SELECT

where there is no LV (Low-Voltage) Secondary or backup protection. They have excellent clearing
capability of ideal low over current with short-circuit performance. Other uses and application of
DIN fuses are in air and gas insulated switchgear, mining, transformers and Feeder sectionalizing.

Blade Type HRC Fuses:

This type of fuses (also known as spade or plug-in fuses) comes in plastic body and two metal caps
to fit in the socket. Mostly, they used in automobiles for wiring and short circuit protection. They
are light in weight. It contains low cutoff current. They are also used for short circuit and backup
protection of motors. They are available in different sizes and shapes with different current rating
capacity, which print on the top.

Fig: Types of HRC Fuses |Image Credit: www.electricaltechnology.org

Re-wirable Fuses:

-
and in the protection of outdoor distribution transformers. It is a fully enclosed type fuse and is
available in a wide range of ratings. The fuse when blown out can be reused after replacing the fuse
element and the circuit can be restored quickly and easily. Renewable fuses are simple in
construction and operation but less reliable than HRC fuses.

Page | 10
Name of Laboratory : Electrical Safety
Lab Subject Code : EEE1021
Name of School : SELECT

Construction of Fuse with Fuse Holder:

Renewable fuse consists of a base and a separate fuse element carrier made of porcelain. The base
consists of two terminals one for incoming supply and the other for the outgoing supply. Similarly
fuse carrier also contains two terminals between which fuse element is connected. Usually one or
more strands of fuse wires are used as fuse element. The fuse base and the carrier are designed
such that each terminals of base coincides with a terminal of the fuse element. The circuit will be
closes only if the fuse carrier is inserted into the base and the fuse element is continuous.

Fig: Fuse Holders

Terminologies

Rated voltage (Un) the maximum nominal voltage that the fuse-link is designed to interrupt.
The fuse-link may have an a.c. rating, a d.c. rating or both
Rated current (In) the maximum value of current that the fuse-link will carry continuously

Rated breaking Capacity is the value of prospective current that a fuse is capable of breaking
at a stated voltage under prescribed conditions of use and behaviour. The fuse link may have an
a.c. breaking capacity, a d.c. breaking capacity or both and this is the maximum fault current that
the fuse-
Conventional non-fusing current (Inf) e-link is

Page | 11
Name of Laboratory : Electrical Safety
Lab Subject Code : EEE1021
Name of School : SELECT

Conventional fusing current (If) is the value of curre n) which causes

operation of the fuse-

Conventional Time -link shall: a) Carry the conventional

non-fusing current without operating and b) Operate within when carrying the conventional
fusing current.
Conventional times for gG, gM, gU, gR and gS fuse-links are
1 hour for ratings of 63A and below
2 hours for ratings above 63A and up to 160A
3 hours for ratings above 160A and up to 400A
4 hours for ratings above 400A
Minimum Breaking Current The minimum value of current that the fuse-link can satisfactorily
interrupt at rated voltage
Pre-arcing time (melting time) the interval of time between the beginning of a current large
enough to cause a break in the fuse element and the instant when an arc is initiated
Arcing time (of a fuse-link) the interval of time between the instant of the initiation of the arc
in a fuse an
Operating time (total clearing time) sum of the pre-arcing time and the arcing time
Power dissipation (of a fuse-link) The power released in a fuse-link carrying a stated value of
electric current (usually rated current) under prescribed conditions of use and behaviour.

Table for Standard Wire Gauge

(A) For Copper as Fuse Wire:

Page | 12
Name of Laboratory : Electrical Workshop
Lab Subject Code : EEE1003
Name of School : SELECT

(B) For Lead-tin Alloy Fuse Wire:

(C) Tinned Copper Fuse Wires:

Page | 13
Name of Laboratory : Electrical Safety
Lab Subject Code : EEE1021
Name of School : SELECT
Name of Laboratory : Electrical Safety
Lab Subject Code : EEE1021
Name of School : SELECT

Fusing Factor:

The ratio of minimum fusing current and the current rating of fusing element

Fusing Factor Class Fusing Factor Application

P 1-1.25 Semi-conductor protection
Q1 1.25-1.5 General purpose;
Now replaced by utilization
category gG which includes a
cable overload test
Q2 1.5-1.75
R Motor starter short protection;
Now replaced by utilization
category gM

Breaking Range and Utilization Category of Fuses:

-links (full-range breaking capacity fuse-link, typically used for overload and short circuit
protection)
-links (partial-range breaking capacity fuse-link, typically used for short circuit protection
only)

-
current characteristics, conventional times and currents

Utilization Classes:

The following Utilization Classes are identified for fuses:

gG - Full range breaking capability, general applications

gM - Full range breaking capability, motor circuit protection
aM - Partial range breaking capability, motor applications
aR/gR - Semiconductor protection, fast acting
gS - Semiconductor protection including cable overload protection

Page | 15
Name of Laboratory : Electrical Safety
Lab Subject Code : EEE1021
Name of School : SELECT
Fuse Types & Applications

Table: Application Chart for Choice of Fuses

Fuse-link characteristics

Time-current characteristic:

It is a curve showing the pre-arcing (melting), or operating, time as a function of current. The time-
current curve has a basic tolerance of ±10% in terms of current

Page | 16
Name of Laboratory : Electrical Workshop
Lab Subject Code : EEE1003
Name of School : SELECT
Cut-

It is a curve showing the cut- urrent as a function of prospective current. Cut-

maximum instantaneous value of current let-through by the fuse-link during one half cycle of
operation under the most onerous conditions of power factor and asymmetry. Note that the
prospective current is expressed in kA r.m.s, whereas the cut-
limitation does occur even when the cut-

I2t characteristic:

- -through energy as a function

of prospective current and voltage, I²t is proportional to energy and is measured in amperes-
squared-seconds (A²s).

Page | 17
Name of Laboratory : Electrical Safety
Lab Subject Code : EEE1021
Name of School : SELECT

Additional Major Aspects of Fuse Rating Selection:

Trip Characteristics:
Quick Acting (F)
Time Lag (T)
Time-lag fuses trip at a slower rate at high currents

Inrush Current:
Many applications will have inrush or peak currents at start-up and sometimes during normal
operation
Inrush current in the application should be measured and used to calculate the proper fuse
I2t value
I2t is the amount of heat energy, in terms of current and time, required to melt the fuse link

Steps for obtaining the Fuse Rating due to Inrush Current:

Step 1: Choose the appropriate waveform that replicates the inrush current related to the
application

Some of the standard wave-shapes are shown in Figure:

Page | 18
Name of Laboratory : Electrical Safety
Lab Subject Code : EEE1021
Name of School : SELECT

Step 2: Calculation of the I2t-value of the application

Application example: Inrush current peak: Ip =

Step 3: Considering Pulse Deration Factor

Continuous exposure to pulses of high current could prematurely age the fuse

Page | 19
Name of Laboratory : Electrical Workshop
Lab Subject Code : EEE1003
Name of School : SELECT

The number of pulses the fuse would be exposed to in the application should also be considered
when choosing a fuse

Application example: Total number of pulses in life cycle: 10,000

Step 4: Selection of the appropriate Fuse Rating based on the I 2t graph of the relevant
manufacturer

Following are the most common applications related to utility of fuses:

Motors, Air-conditioners, Home distribution boards, General electrical appliances and devices,
Laptops, Cell phones, Game systems, Digital cameras, LCD monitors, Power convertors, Scanners etc

Page | 20
Name of Laboratory : Electrical Safety
Lab Subject Code : EEE1003
Name of School : SELECT

Circuit Diagram:

Procedure for Calculating Fuse Rating and Range Selection:

A. Traditional Method:
Step 1: For the given application use the Fusing Factor to determine the nearest fuse rating
Step 2: Obtain the appropriate gauge (SWG) of the fuse link (for low rating tinned lead
and for higher current ratings tinned copper)
Step 3: Check the gauge with gauge measurement slider
Step 4: Install the rewirable fuse link into the fuse holder
B. Utilizing Characteristic Curves:
Step 1: For the given application use the application chart to determine the application
category of fuse
Step 2: Use the appropriate Current Time characteristic curve to fix the fuse rating
Step 3: Obtain the appropriate gauge (SWG) of the fuse link (for low rating tinned lead
and for higher current ratings tinned copper)
Step 4: Check the gauge with gauge measurement slider
Step 5: Install the rewirable fuse link into the fuse holder

Page | 21