Fuses

In electronics and electrical engineering a fuse (from the Latin "fuses" meaning to melt) is a type of
sacrificial over current protection device. Its essential component is a metal wire or strip that melts when
too much current flows, which interrupts the circuit in which it is connected. Short circuit, overload or
device failure is often the reason for excessive current.
A fuse interrupts excessive current (blows) so that further damage by overheating or fire is prevented.
Wiring regulations often define a maximum fuse current rating for particular circuits. Over current
protection devices are essential in electrical systems to limit threats to human life and property damage.
Fuses are selected to allow passage of normal current and of excessive current only for short periods.
In 1847, Breguet recommended use of reduced-section conductors to protect telegraph stations from
lightning strikes; by melting, the smaller wires would protect apparatus and wiring inside the building.
variety of wire or foil fusible elements were in use to protect telegraph cables and lighting installations as
early as 1864
A fuse was patented by Thomas Edison in 1890 as part of his successful electric distribution system

Operation
A fuse consists of a metal strip or wire fuse element, of small cross-section compared to the circuit
conductors, mounted between a pair of electrical terminals, and (usually) enclosed by a non-conducting
and non-combustible housing. The fuse is arranged in series to carry all the current passing through the
protected circuit. The resistance of the element generates heat due to the current flow. The size and
construction of the element is (empirically) determined so that the heat produced for a normal current
does not cause the element to attain a high temperature. If too high a current flows, the element rises to a
higher temperature and either directly melts, or else melts a soldered joint within the fuse, opening the
circuit.
When the metal conductor parts, an electric arc forms between the un-melted ends of the element. The arc
grows in length until the voltage required to sustain the arc is higher than the available voltage in the
circuit, terminating current flow. In alternating current circuits the current naturally reverses direction on
each cycle, greatly enhancing the speed of fuse interruption. In the case of a current-limiting fuse, the
voltage required to sustain the arc builds up quickly enough to essentially stop the fault current before the
first peak of the AC waveform. This effect significantly limits damage to downstream protected devices.
The fuse element is made of zinc, copper, silver, aluminum, or alloys to provide stable and predictable
characteristics. The fuse ideally would carry its rated current indefinitely, and melt quickly on a small
excess. The element must not be damaged by minor harmless surges of current, and must not oxidize or
change its behavior after possibly years of service.
The fuse elements may be shaped to increase heating effect. In large fuses, current may be divided
between multiple strips of metal. A dual-element fuse may contain a metal strip that melts instantly on a
short-circuit, and also contain a low-melting solder joint that responds to long-term overload of low
values compared to a short-circuit. Fuse elements may be supported by steel or Nichrome wires, so that
no strain is placed on the element, but a spring may be included to increase the speed of parting of the
element fragments.
The fuse element may be surrounded by air, or by materials intended to speed the quenching of the arc.
Silica sand or non-conducting liquids may be used.

Characteristic Parameters
Rated current IN
A maximum current that the fuse can continuously conduct without interrupting the circuit.
Speed
The speed at which a fuse blows depends on how much current flows through it and the material of which
the fuse is made. The operating time is not a fixed interval, but decreases as the current increases. Fuses
have different characteristics of operating time compared to current, characterized as "fast-blow",
"slow-blow" or "time-delay", according to time required to respond to an over current condition. A
standard fuse may require twice its rated current to open in one second, a fast-blow fuse may require
twice its rated current to blow in 0.1 seconds, and a slow-blow fuse may require twice its rated current for
tens of seconds to blow.
Fuse selection depends on the load's characteristics. Semiconductor devices may use a fast or ultrafast
fuse since semiconductor devices heat rapidly when excess current flows. The fastest blowing fuses are
designed for the most sensitive electrical equipment, where even a short exposure to an overload current
could be very damaging. Normal fast-blow fuses are the most general purpose fuses. The time delay fuse
(also known as anti-surge, or slow-blow) are designed to allow a current which is above the rated value of
the fuse to flow for a short period of time without the fuse blowing. These types of fuse are used on
equipment such as motors, which can draw larger than normal currents for up to several seconds while
coming up to speed.
The I2t value
A measure of energy required to blow the fuse element and so a measure of the damaging effect of over
current on protected devices; sometimes known as the let-through energy. Unique I2t parameters are
provided by charts in manufacturer data sheets for each fuse family. The energy is mainly dependent on
current and time for fuses.

Breaking capacity
Breaking capacity or interrupting capacity is the current that a fuse, circuit breaker, or other electrical
apparatus is able to interrupt without being destroyed or causing an electric arc with unacceptable
duration. The prospective short circuit current which can occur under short circuit conditions should not
exceed the rated breaking capacity of the apparatus. Otherwise breaking of the rated current cannot be
guaranteed. Breaking capacity current corresponds to a voltage, so an electrical apparatus may have more
than one breaking capacity current, according to the voltage. Breaking current may be stated in terms of
the total current or just in terms of the alternating-current (symmetrical) component. Since the time of
opening of a fuse or switch is not coordinated with the reversal of the alternating current, in some circuits
the total current may be offset and can be larger than the alternating-current component by itself.

Choosing Breaking capacity

Calculating a suitable breaking capacity involves determining the supply impedance and voltage. Supply
impedance is calculated from the impedance of the elements making up the supply system. Customers of
an electrical supply utility can request the maximum value of prospective short circuit current available at
their point of supply. Networks involving multiple sources of current, such as multiple generators, electric
motors, and with variable interconnections may be analyzed using computer software. A system study
will generally consider the maximum case of additions of generation and interconnection out to some
projected horizon year, to allow for system growth during the useful life of the studied installation.
Since practical calculations involve a number of approximations and estimates, some judgment is
required in applying the results of a short-circuit calculation to the selection of apparatus.
Some applications have low short circuit current so any fault current protector will suffice. This is typical
for supplies from miniature transformers as used in control circuits. In large systems such as industrial
power centers or utility networks, fault currents can be very high and selection of a suitably rated device
is important.
Rated voltage
Voltage rating of the fuse must be greater than or equal to what would become the open circuit voltage.
For example, a glass tube fuse rated at 32 volts would not reliably interrupt current from a voltage source
of 120 or 230 V. If a 32 V fuse attempts to interrupt the 120 or 230 V source, an arc may result. Plasma
inside that glass tube fuse may continue to conduct current until current eventually so diminishes that
plasma reverts to an insulating gas. Rated voltage should be larger than the maximum voltage source it
would have to disconnect. This requirement applies to every type of fuse.
Rated voltage remains same for any one fuse, even when similar fuses are connected in series.
Connecting fuses in series does not increase the rated voltage.
Medium-voltage fuses rated for a few thousand volts are never used on low voltage circuits, because of
their cost and because they cannot properly clear the circuit when operating at very low voltages.