Fuse

 Fuse is advice used to protect the circuits and equipments against

overload and short circuits.
 Fuse element materials having low melting point, high conductivity .
 Fuse operation based on the heating effect of the current when flows
through element. In normal operation the heat dissipated rapidly into
the surrounding air and element remains at below its melting point.
when fault occur in the electric circuit, the current exceeds the limiting
value and cannot be dissipated heat fast enough and element melts
and breaks the circuit.
 Its rating can start from few mA to several kA.
 Many forms and shapes depending on
its application.
 Fuse has inverse time current
characteristics.
Principle of Electrical Fuse
•The primary use of an electric fuse is to protect electrical equipment from excessive current and to prevent
short circuits or mismatched loads.
•Electrical fuses play the role of miniature circuit breakers.
•Apart from protecting equipment, they are also used as safety measures to prevent any safety hazards to
humans.
• Function of Fuse
• A fuse is a device that provides overcurrent protection to the functional electrical circuit.
• Acts as a barrier between the electric circuit and the human body.
• Prevents device failure due to faulty circuit operation
• Fuse prevents short-circuits
• Prevents overload and blackouts
• Prevents damage that is caused due to mismatched loads
• The markings on the fuse carry information such as the Ampere rating, voltage rating, and
interruption rating.
• Types of Fuses
• There are different types of fuses available in the market and they can be
categories on the basis of Different aspects.
• Good to know: Fuses are used in AC as well as DC circuits.
DC Fuses
In a DC system, when the metallic wire melts because of the heat generated by the over current, then Arc is
produced and it is very difficult to extinguish this arc because of DC constant value. So in order to minimize
the fuse arcing, DC fuse are little bigger than an AC fuse which increases the distance between the
electrodes to reduce the arc in the Fuse.

AC Fuses
On the other hand, i.e. in the AC system, voltage with 60Hz or 50Hz frequency changes its amplitude from
zero to 60 times every second, so arc can be extinct easily as compared to DC. Therefore, AC fuses are a
little bit small in sizes as compared to DC 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 are required. They are available up to 600A and 600V AC and
widely used in industries, commercial as well as home distribution panel.
There are two types of Cartridge fuses. 1. General purpose fuse with no time delay and 2. Heavy-duty
cartridge fuses with time delay.
• Advantage
The wire is enclosed in a cartridge-type container.
The wrong size of fuse cannot be fitted since it with different size for different
current
 The fuse wire does not deteriorate and is more reliable in operation
• HRC (High Rupturing Capacity) Fuse or Link Type Cartridge Fuse
It is a cartridge-type with silver element connected between two
end- contacts of a ceramic tube filled with a special quartz powder.
 This type of fuse is very reliable in performance and does not deteriorate and has a high speed
 When the fuse blows is a silver (which rapidly melt ) produced with the filling powder high-
resistance material are formed in of operation and the path of the arc, causing it to be extinguished. ,ability
to safely interrupt short circuit currents of much higher values (higher rupturing capacity).

Automotive, Blade Type & Bolted Type Fuses

These types of fuses (also known as spade or plug-in fuses) come in plastic body and two metal caps to fit in
the socket. Mostly, they are used in automobiles for wiring and short circuit protection. Fuse Limiters, Glass
Tube (also known as Bosch Fuse) are widely used in automotive industries. The rating of automobile fuses are
low as 12V to 42V.
• SMD Fuses (Surface Mount Fuse), Chip , Radial, and Lead Fuses
• SMD Fuses (Surface Mount Device) and the name derived from (SMT
Surface Mount Technology) are chip types of fuses (also known as electronic
fuse) are used in DC power applications like Hard Drive, DVD players,
Camera, cell phones etc where space playing an important role because
SMD fuses are very tinny in size and hard to replace as well.
Rewirable Fuses
• The most famous kit-kat fuse (also known as rewireable fuse) mostly used in industries
and home electrical wiring for small current applications in Low Voltage (LV) systems.
• Rewireable fuse contains 2 basic parts. The inner fuse element as fuse carrier made of
tinned copper, Aluminum, Lead etc and the base made of porcelain having the IN and
OUT terminals which is used to be in series with the circuit to protect.
• The main advantage of a rewireable fuse is that It can be rewired easily in case it is blown
due to short circuit or over current which melts the fuse elements. Simple, put another
wire of fuse elements with the same rating as before.
Thermal Fuses
• Thermal fuse is a one time used only fuse. They are temperature sensitive fuse and the
fuse element is made of temperature sensitive alloy. They are known as Thermal Cutouts
(TCO) or Thermal Links.
• In a thermal fuse, the fuse element holds a mechanical spring contact which is normally
closed. When high currents due to over current and short circuit flow through the
elements of the fuse, the fuse elements melts down which lead to release the spring
mechanism and prevent the arc and fire and protect the connected circuit.
• Resettable Fuses
• Resettable fuse is a device, which can be used 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 resettable fuses is overcome where manually replacing fuses is
difficult or almost impossible, e.g. fuse in the nuclear system or in an
aerospace system.
 MCB
• A miniature circuit breaker (MCB) is an Electrical Switch that automatically
switches off the electrical circuit during an abnormal condition of the network
means an overload condition as well as a faulty condition.
• It can be reclosed without any manual replacement. In the case of a fuse, once
it has been operated, it must be replaced or rewired, depending on the type
of the MCB. . Nowadays we use an MCB in a low-voltage electrical network
instead of a fuse.
• MCB are intended to prevent damage to an electrical circuit as a result of
excess current. They are designed to trip during an overload or short circuit to
protect against electrical faults and equipment failure.
A Miniature Circuit Breaker (MCB) typically consists of the following components:
• Main contacts: These are the contacts that carry the load current and are
connected to the incoming and outgoing wires of the circuit.
• Housing: The housing is the protective casing that houses the MCB components and
provides insulation between live parts and other electrical components.
• Trip Indicator: An MCB typically has a visual indicator that shows whether the
breaker is in the “on” or “off” position.
• Auxiliary contacts: Some MCBs have additional contacts that can be used to switch
auxiliary loads or provide signaling functions.
• Trip spring: This is the spring mechanism that holds the MCB contacts in the “on”
position. When the trip unit operates, the trip spring releases, allowing the contacts
to separate and break the circuit.
Trip Unit: This is the core component of an MCB, which monitors the current
flowing through the circuit and trips the breaker in case of an over-current or short-
circuit. The trip unit consists of a bimetallic strip, a magnetic actuator, and an
operating mechanism. MCBs are typically designed for low-power applications,
ranging from 0.5A to 125A.
Whenever continuous overcurrent flows through MCB, the bimetallic strip is heated and deflects
by bending. This deflection of the bi-metallic strip releases a mechanical latch.
As this mechanical latch is attached to the operating mechanism, it causes to open the
miniature circuit breaker contacts, and the MCB turns off thereby stopping the current to flow in
the circuit. To restart the flow of current the MCB must be manually turned ON.
This mechanism protects from faults arising due to overcurrent or overload and short circuits.
But during short circuit conditions, the current rises suddenly, causing electromechanical
displacement of the plunger associated with a tripping coil or solenoid. The plunger strikes the
trip lever causing the immediate release of the latch mechanism consequently opening the
circuit breaker contacts. This was a simple explanation of a miniature circuit breaker’s working
principle.
An MCB is very simple, easy to use, and is not generally repaired. It is just easier to replace.
The trip unit is the main part, responsible for its proper working. There are two main types of
trip mechanisms.
A bi-metal provides protection against overload current and an electromagnet provides
protection against electric short-circuit current.
 Different Types of MCBs
There are 6 types of MCBs, they are:
• A Type
• B Type
• C Type
• D Type
• K Type
• Z Type
• A Type MCB trips off the circuit when the current exceeds 2-3 times the actual current rating. A
type MCB – Miniature Circuit Breaker is highly sensitive to the short circuit, and hence we can find
its application in the manufacturing of semiconductors.
• B Type MCB trips off the circuit when the current exceeds 3-5 times the current flow and finds its
application in cable protection.
• C Type MCB trips off the circuit when the current exceeds 5-10 times the actual current flow and
finds its application in domestic as well as commercial appliances like transformers, fluorescent
lighting circuits, and IT equipment like personal computers, servers, and printers.
• D Type MCB trips off the circuit when the current exceeds 10-20 times the current flow and offers
high resistance. It finds its application in motors.
• K Type MCB can withstand up to 8-12 times the current flow and finds its application in heavy-duty
load devices like compressors, winding motors, and X-ray machines.
 ELCB
• ELCB or Earth Leakage Circuit Breaker (ELCB) is a protection device that protects
against earth leakage. Initially, the earth leakage circuit breaker were voltage
detection devices, now they are switched to current sensing devices. The current
ELCB is renamed as RCCB or RCD while the voltage ELCBs are still known as ELCB but
they are obsolete.
What is Earth Leakage?
The electrical current that flows from the live conductor to the earth through an
unintended path is called earth leakage. It may flow between their poor insulation or
through a person’s body and cause electrical shock. The consequence of electrical
shock may prove fatal if the leakage current exceeds the only 30mA. Therefore,
protection devices are used to disconnect the power source when such current
leakage is detected
Causes of Earth Leakage?
Earth leakage can occur due to various reasons. It can occur due to damaged
insulation of the live conductor or broken conductors. It can also occur when the live
conductor comes in contact with the body of the equipment (if the equipment is not
properly grounded). Upon touching the conductor or the equipment, the current can
pass to the earth through the person’s body.
ELCB or Earth Leakage Circuit Breaker is a type of circuit breaker that is used for protection against leakage
current. it breaks the circuit and disconnects the power supply to the load when it senses the leakage current. The
earth leakage can cause electrical shocks that can be fatal.
ELCB is mainly used for protection against electrical shock. They do not offer protection against overloading or
short circuit. Therefore, they must be used in series with an MCB (miniature circuit breaker).

Function of ELCB
ELCB is a safety device whose main function is to prevent
electrical shock. It monitors the leakage current that flows out of
the circuit through any unintended path. It cannot protect against
overloading or short circuit current.

Operation of ELCB
Under normal conditions, the current from the source flows into
the load through the live wire and flows out of the load through
the neutral wire. In fact, both currents are equal in amount. If
the current leaks through any unintended path, an imbalance
between the live and neutral wire occurs. The ELCB can sense
the imbalance using a current transformer and break the
contacts using an electromagnetic relay.
There are two types of ELCB classified based on its
operation principle;
•Voltage ELCB
•Current ELCB
Both types of ELCBs detect the leakage current but
their sensitivity and the level of protection they offer
are different. Voltage ELCB was invented before the
current ELCB. voltage based ELCB is inferior to
current ELCB. Therefore, to avoid confusion, the
voltage ELCB is renamed ELCB while the current
ELCB is renamed RCCB or RCD.
Voltage ELCB
Voltage ELCB operates on the voltage level between the
earth and the body of the equipment. The voltage difference
is used to detect the leakage current and instantly break the
circuit. It has terminals for both phases and neutral on both
supply and load sides. It has two extra terminals that connect with
the equipment’s body and the earth. These terminals are actually
connected with the electromagnetic relay and they play a vital
role in breaking the circuit during current leakage.
Working Principle
One of the terminals of the relay coil is directly
connected to the earth while the other terminal is
connected to the body of the equipment. The coil can
sense the voltage difference between the earth and the
body of the equipment.
If the live wire breaks or its insulation fails and comes in
contact with the body of the equipment, a voltage
difference appears across the terminals of the coil. As a
result, the current starts to flow through the coil and it is
energized. The relay starts to generate electromagnetic
force. When the current exceeds a certain limit, the
relay produces sufficient force to pull the latch. By
doing so, the latch break opens the contacts and
disconnects the power supply to the equipment and Advantages of voltage ELCB
prevents electrical shock.
•It helps in protection against electrical shocks.
Therefore, the earth connection is necessary as the
•They are less sensitive and do not trip
relay only operates when the leakage current flows
unnecessarily.
through it. if the current leaks through any other parts of
•They are less expensive.
the circuit and flows through any other unintended path,
it will not break the circuit as the current must flow
through the relay in order to break the circuit.
• Disadvantages of voltage ELCB
• It cannot sense the current leakage from phase to any other earthed
body.
• It cannot prevent electrical shock in case of touching the phase conductor
directly.
• It only trips when the leakage current flows through the earth conductor.
• It requires an extra connection with the body of the equipment and earth.
• It is less sensitive and cannot detect low leakage current.
• Electrical equipment that normally leaks voltage might trip ELCB
unnecessarily.
 RCCB
Residual Current Circuit Breaker or RCCB is basically a gadget that senses current and disengages any low
voltage (uneven current) circuit whenever a fault occurs. The main purpose of installing a Residual Current Circuit
Breaker fundamentally is to protect people from electric shocks or death caused by them
It avoids accidents by disengaging the main circuit just in a fraction of a second. The working of RCCB
electrical devices is based on the principle – Kirchhoff’s Current Law, which means that the incoming and the
outgoing current in the circuit should be equal.

Principle behind RCCB

RCCB, known as Residual Current Circuit Breakers, operates on the
principle of detecting and responding to imbalances in electrical currents.
The key principle involves continuously monitoring the current flowing
through the live and neutral conductors. In a balanced circuit, where the
current flowing in is equal to the current flowing out, there is no residual
current. However, if there's an imbalance, indicating leakage to the ground
or an unintended path, the RCCB detects the difference in currents. Upon
sensing such a discrepancy, the RCCB rapidly disconnects the circuit,
preventing potential electric shocks or fires. This safety mechanism makes
RCCBs crucial components in electrical systems, enhancing protection
against electrical hazards.
Some of the advantages of using RCCBs are:
• Electrical Safety: RCCBs provide effective protection against electric shocks by swiftly disconnecting the circuit in the
presence of a residual current, minimizing the risk of injury.
• Fire Prevention: By promptly detecting and isolating faulty circuits with leakage currents, RCCBs contribute significantly to
preventing electrical fires.
• Equipment Protection: RCCBs safeguard electrical appliances and equipment by preventing damage caused by faulty
currents, ensuring the longevity of devices.
• Compliance with Standards: The use of RCCBs aligns with electrical safety standards, meeting regulatory requirements and
enhancing overall electrical system safety.
• Versatility: RCCBs are versatile and can be installed in various electrical installations, offering protection in residential,
commercial, and industrial settings.
• Early Detection: The rapid response of RCCBs to residual currents allows for early detection and mitigation of potential
electrical hazards, ensuring a safer environment.
There are two types of RCCBs, a 2 Pole RCCB and a 4 Pole
RCCB:
2 Pole RCCB
It is utilized in a single-phase supply which only contains a neutral wire and a live
wire. It has two ends and at those ends, the neutral wire and live wire are connected.
With the help of a rotary switch, you can switch the RCCB on and off. It also has a
test button that assists in periodically testing the functionality of the RCCB.
4 Pole RCCB
• 4 Pole RCCB is utilized in a 3-phase supply connection that includes a neutral wire
and 3 phase wires. Again this has two ends where both the neutral wire and 3 phase
wires are connected. This is the only difference between the 2 and 4 poles RCCB, the
rest of the work is similar.

MCCB
Mccb stands for Moulded Case Circuit Breaker, which is a protective device that controls the flow of electrical
current. MCCBs are used in high-energy regions, such as commercial and industrial applications, and when
load currents exceed the limit of a miniature circuit breaker (MCB). MCCBs are an advanced version of
traditional circuit breakers, offering enhanced features, performance, and reliability. MCCBs are capable of
handling extremely high currents, up to 1000A. MCCBs come with an interrupt rating between 10k to 200k
amperes, whereas the interrupt rating of an MCB is up to 1800 amperes.
• Molded Case Circuit Breaker Working Principle
• The main low voltage circuit breaker contact is operated electrically or manually. The
main contact in the closing position is locked by the free release mechanism locks after
the main contact is closed. With the main circuit, the thermal element of the thermal
release and the coil of the over-current release are in series. With the power supply,
the coil of the under-voltage release is in parallel.
To make the free tripping mechanism act, the armature of the over-current
release is closed when the circuit is seriously overloaded or short-circuited. The
main circuit is disconnected by the main contact.
The thermal element of the thermal release will be heated When the electronic
circuit is overloaded, which will push the free release mechanism to act and bend
the bimetallic sheet. The main circuit will be disconnected by the main contact.
The armature of the under-voltage release releases when the circuit is under voltage. As a result, the main
contact disconnects the main circuit, and the free release mechanism act.
To make the main contact will disconnect the main circuit and free tripping mechanism act, the armature of the
shunt release will be closed when the shunt release button is pressed.
 Difference between MCB and MCCB Difference between RCCB and ELCB

[Link] MCB MCCB [Link] RCCB ELCB

It stands for Miniature Circuit It stands for Molded
1
Breaker. Case Circuit Breaker.
RCCB refers to ear stands
ELCB stands for Electric
Rated current not more than Rated Current up to 1. for Residual Current Circuit
2 Leakage Circuit Breaker.
125 Ampere. 1600A Breaker.

Their interrupting
Its interrupting current rating is ELCB refers to voltage
3 current ranges from It is a new name and refers
under 10KA 2. operated earth leakage
around 10KA -85KA to current operated devices.
device.
MCCB is mainly used It ensures 100% detection of It is not preferable as it can
Judging from their power
for both low and high leakage current& is available only detect current that flow
capacities, MCB is mainly used 3
4 Breaking capacity to sense the AC as well as back through the main earth
for low Breaking capacity
requirements mainly DC leakage current. wire.
requirement mainly domestic.
industrial.
RCCB has no connection ELCB is working based on
with the earth wire and that’s Earth leakage current. These
Its trip characteristics are Its trip current may be why it can trip when both devices measured the
normally not adjustable since fixed as well as 4 currents (phase and neutral) voltage on the earth
5 are different and it conductor; if this voltage was
they basically cater to low adjustable for overload
circuits. and magnetic setting. withstands up to both the not zero this indicated a
currents are same. current leakage to earth.
1)The primary function of a fuse is to
a)Open the circuit b) Protect the appliance
c) Protect the line d)Prevent excessive currents from
flow through the circuit
• 2) The fuse rating is expressed in terms of
a) Current b)Voltage
c)VAR d)KVA
3)Fuses have got advantages of
a)Cheapest type of protection b)Inverse time current characteristic
c) No Maintenance d)Current limiting effect under short-
circuit conditions
e)All of the above
4)A fuse wire possesses
a)Direct time characteristics b)Inverse time characteristics
c)Either of the above d)None of the above
5) The fuse wire in DC circuit is inserted in
a) Negative circuit only b) Positive circuit only
c) Both A and B d) Either A or B

6)Which of the following is used in liquid fuses?

a)Transformer oil b)Sulphur hexafluoride
c)Distilled water d)Carbon tetrachloride

7)A fuse element should have......... melting point

a)High b)Low c) Same
d)None of the above e)All of the above
8)The expansion form of RCCB is
a)Residual current circuit breaker b)Residual circuit current breaker
c)Residual current control breaker c)Residual control circuit breaker
9)The expansion form of MCCB is
a)Moulded case circuit breaker b)Main case circuit breaker
c)Main control circuit breaker d)Main current circuit breaker