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Current Limiting Fuses: Application Considerations and Cautions

Frank Muench, Cooper Power Systems, Member IEEE

AbstractIEEE C37.48.1 [1] covers key concepts in the use of current limiting fuses. The 5th section of the document provides insight into the proper application considerations and the cautions that need to be followed when using current limiting fuses. It covers typical application of the fuse in normal protection schemes for various types of equipment as well as the physical considerations to use in applying these fuses. Again the goal was to have a tutorial document that teaches the basis for the rules of thumb application guides used in the industry, rather than just noting that certain considerations must be followed.

equipment. The guide discusses considerations for each type of equipment. The equipment includes the following items: Transformers Feeders and sections of the system Capacitors Motors and circuits with motors on them Each of these types of equipment is discussed in a similar way. III. TYPICAL APPLICATION TRANSFORMER PROTECTION There is a preview of the particular application considerations such as inrush current, cold load pick-up factors, normal loading and overloading conditions, and through fault requirements. The interactions of the fuse and device being protected in key areas such as peak arc voltages produced during fuse interruptions versus the voltage withstand of the systems and device being protected is also discussed. Each of the devices has its own requirements, for instance rather than inrush currents, motor starter fuses experience current pulses, so a pulse withstand capability is required of a fuse protecting motors. As an example, the transformer application section is described below. There are several factors to consider in applying transformers: Inrush (magnetizing) current Load pick-up Transformer loading and overloading Through fault conditions Maximum arc voltages The following paragraphs present a condensed version of the material that is part of the guide. Much of fuse application and coordination work is done using TCCs (Time Current Curves). The curves are plotted on log/log paper. They show both the minimum time required for the fuse to melt at any given current level and the maximum time required for the fuse to melt and then interrupt the circuit at any given current. These curves are compared to those of other protective devices in the circuit and to curves that show the time current relations that would cause damage to the protected equipment. When the core of a transformer is magnetized, currents

I.

OVERVIEW

This section is designed to teach both the electrical and physical considerations used to properly apply current limiting fuses. The electrical applications discussion starts with a description of how fuses respond to current. This is followed by detailed descriptions of how to protect various types of equipment that make up an electric power distribution system using current limiting fuses. It closes with discussion of the physical considerations that must be taken into account when using current limiting fuses. In the guide this requires 12 pages of text. This overview will reduce this to 2 pages by covering only the high points, providing a broad overview. Much of the information is based on common sense, especially when used in the context of the other sections of the document. II. ELECTRICAL ASPECTS OF FUSE APPLICATION The guide opens with a discussion of normal load conditions and makes the point that for most or all of the fuses life it carries load current (as well as some overloads). Its primary function is to carry current. If the fuse is exposed to higher currents because of severe overloads or faults on equipment it is protecting, the fuse will melt. Care must be taken to use the right type of fuse for each application so that when it melts, it can also interrupt the current flow, isolating the overloaded or failed parts of the system from the rest of the system. This preserves the majority of the system and provides protection for the public and system operators from the effects of the failure. Current limiting fuses are used to protect many types of

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much higher than normal 25 times the rated current for example, can flow for short times - .01 s or less. After the core is magnetized, the current would fall to normal load current levels. The fuse must be selected to withstand this short time transient, without having the fuse element melt. If the fuse element were to melt open during this transient, and the current were to fall to normal load current levels, the fuse would be expected to be unable to interrupt the load current and probably burn up. This is the result of the slow burnback of the element, from a single melt point and the high heat released by the arc. These factors combine to make this a very difficult challenge for the fuse. The way to prevent this failure mode is to use the data on the fuse TCC (timecurrent-curves) to be sure the fuse can withstand the transient inrush current. Load pick up is similar to the inrush condition. When a circuit is de-energized and then re-energized, higher than normal current can flow for extended time periods. One cause of this higher than normal current results from a lack of diversity, i.e. heating systems in several houses served by the transformer running simultaneously rather than separately. Various conditions can cause motors being connected to the transformer to draw higher than normal current for periods of time. Rapidly cycling motor starting currents can also create heating in fuses. If the duration and magnitude of the current is high enough, the fuse can melt open. In this case the fuse can either fail or if the high current persists for a long enough time the fuse may successfully interrupt the circuit. This guide presents the typical practices for comparing multiples of the load currents at selected times to the TCC curve of the fuse. By selecting a fuse that is large enough, damage to the fuse from load pick-up can be avoided. Transformer loading and overloading draws current through the fuse. Transformer standards in the C57 series provide guidance as to the effect of overloads on transformer life. This is represented by safe loading curves such as those shown in IEEE Std C57.93-1995. The Maximum Clearing TCC of the fuse should show that the fuse will operate before this damage curve is breached, preventing damage to the transformer. Transformers can also experience through-faults due to faults on the secondary of the transformer. Again there are standards, such as IEEE Std C57.109-1993, that present a through fault duration guide. The TCC of the fuse should be compared to the damage curve of the transformer to be sure that the fuse will melt and interrupt the circuit before the transformer is exposed to conditions that will damage it. There is, of course, more detail and background information in the actual document, with the terms and background being explained. Each of the most common applications listed earlier is explained through an in depth discussion in this section of the guide. IV PHYSICAL MOUNTING

The other major set of considerations come from the needs to properly install and connect these fuses in to the power distribution circuit. There are many different fuse types and many of these have characteristics that limit the fuse application to very specific requirements. Some of the mounting environments that are reviewed in the guide include: Under oil, in the transformer or switchgear case In dry well canisters, which are sealed with limited heat transfer allowed, In clips or hinged mountings in air, inside transformer cable termination enclosures. Outdoors in air, in the weather. Each of these environments place requirements on the fuse to be sure it will function correctly. The need for seals, for weather resistant coatings, or mating contact points all need to be considered when applying fuses. The guide explains many of these requirements. Other areas discussed in the guide include cautions in the area of safe handling and avoiding physical damage to the fuses during use. Again, much of this information is straightforward and based on common sense. However, to be sure it is not overlooked, it was necessary to include a discussion of this material. Other environment/fuse interactions are reviewed in the guide. Matching the types of fuses to the typical environment is critical to the safe and proper fuse application. By tying together how these fuses work, the application guidelines, descriptions of the fuse classes and types, and coordination rules, the guide provides a context to understand the reasons behind the guidelines and rules for proper application. It is the teaching aspect of the guide that makes it unique. Other key considerations that are unique to current limiting fuses are also covered. For example, the effects that current limiting fuses have on power quality is a key area thats briefly discussed. Through the peak arc voltage generated as the fuse interrupts, system voltage is supported. With other types of protection such as expulsion fuses or reclosers, the voltage dip that can result from a solid fault on the system can approach 100% of the driving voltage and can be present for several cycles. This can cause loss of computer memories, interrupt manufacturing process and cause the frustrating flashing VCR lights. V SUMMARY The need to organize the document into a comprehensible whole requires the discussion to be broken into specific sections. Scanning the contents page will help one find the way to any particular area of interest. The working group believes that the document is a key tool for anyone who needs to learn about current limiting fuse application to get the data they need. It can benefit engineers with new areas of

responsibility, experienced engineers who have been assigned new responsibility, or anyone that has used the various rules of thumb without understanding the reasons for them. If the document is received and used, it will remain available and will be updated and revised to improve it. VI REFERENCES [1] IEEE Guide for the Operation, Classification, Application and Coordination of Current-Limiting Fuses with Rated Voltages 1-38 kV, IEEE C37.48.1-2002 [2] IEEE Guide for Installation of Liquid-Immersed Power Transformers, IEEE C57.93-1995 [3] IEEE Guide for Liquid-Immersed Transformers Through-Fault-Current Duration, IEEE C57.109-1993 VII BIBLIOGRAPHY

Frank Muench is a member of IEEE and has authored several papers on electric power distribution products. He was chairman of the working group that developed this guide at the time of balloting. The recipient of over a dozen US patents, he has over 30 years of experience in the design and application of protective equipment and components used to protect, connect and operate the high voltage electrical system. He is currently the Manager of Line Protection Devices Engineering for Cooper power Systems, Waukesha, WI.