9/5/23, 5:57 PM SMPS -- FUSE SELECTION

1 INTRODUCTION

Fuses (fusible wire links) are one of the oldest and most universally
used overload protection methods. However, the fuse sometimes
does not get the close attention it deserves for a thorough
understanding of its characteristics.

Modern fuse technology is an advanced science; new and better

fuses are continually being developed to meet the more demanding
requirements for protection of semiconductor circuitry. To obtain the
most reliable long-term performance and best protection, a fuse
must be knowledgeably chosen to suit the application.

2 FUSE PARAMETERS

From an electrical standpoint, fuses are categorized by three major

parameters: current rating, voltage rating, and most important, "let-
through" current, or I^2 t rating.

Current Rating

It is common knowledge that a fuse has a current rating and that this
must exceed the maxi mum DC or rms current demanded by the
protected circuit. However, there are two other ratings that are
equally important for the selection of the correct fuse.

Voltage Rating

The voltage rating of a fuse is not necessarily linked to the supply

voltage. Rather, the fuse voltage rating is an indication of the fuse's
ability to extinguish the arc that is generated as the fuse element
melts under fault conditions. The voltage across the fuse element
under these conditions depends on the supply voltage and the type
of circuit. For example, a fuse in series with an inductive circuit may
see voltages several times greater than the supply voltage during
the clearance transient.

Failure to select a fuse of appropriate voltage rating may result in

excessive arcing during a fault, which will increase the "let-through"
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energy during the fuse clearance. In particularly severe

circumstances, the fuse cartridge may explode, causing a fire
hazard.

Special methods of arc extinction are utilized in high-voltage fuses.

These include sand filling and spring-loaded fuse elements.

"Let-Through" Current (I^2t Rating)

This characteristic of the fuse is defined by the amount of energy

that must be absorbed by the fuse element to cause it to melt. This
is sometimes referred to as the pre-arcing let-through current. To
melt the fuse element, heat energy must be absorbed by the
element more rapidly than it can be conducted away. This requires a
defined current and time product.

For very short time periods (less than 10 ms), very little heat is
conducted away from the fuse element, and the amount of energy
necessary to melt the fuse is a function of the fuse element's specific
heat, its mass, and type of alloy used. The heat energy absorbed by
the fuse element has units of watt-seconds (joules), and is
calculated as I^2 R t for a particular fuse. As the fuse resistance is a
constant, this is proportional to I^2 t, normally referred to as the I^2 t
rating for a particular fuse or the pre-arcing energy.

For longer periods, the energy required to melt the fuse element will
vary according to the element material and the thermal conduction
properties of the surrounding filler and fuse housing.

In higher-voltage circuits, an arc will be struck after the fuse element

has melted and a further amount of energy will be passed to the
output circuit while this arc is maintained.

The magnitude of this additional energy is dependent on the applied

voltage, the characteristic of the circuit, and the design of the fuse
element. Consequently, this parameter is not a function of the fuse
alone and will vary with the application.

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The I^2 t rating categorizes fuses into the more familiar "slow-blow",
normal, and "fast-blow" types. Figure 1.5.1 shows the shape of a
typical pre-arcing current/time let through characteristic for each of
the three types. The curve roughly follows an I^2 t law for periods of
less than 10 ms. The addition of various moderators within the fuse
package can greatly modify the shape of this clearance
characteristic. It should be noted that the I^2 t energy (and hence
the energy let-through to the protected equipment) can be as much
as two decades greater in a slow-blow fuse of the same DC current
rating! For example, the I^2 t rating can range from 5 A^2 s for a 10-
A fast fuse to 3000 A^2 s for a 10-A slow fuse.

FIG. .5.1 Typical fuse I^2 t ratings and pre-arcing fuse clearance
times for fast, normal, and slow fuse links.

The total let-through energy of the fuse (pre-arcing plus arcing) also
varies enormously.

Further, it depends on the fusible link material, construction of the

fusible element, applied voltage, type of fault, and other circuit-linked
parameters.

3 TYPES OF FUSES

Time-Delay Fuse (Slow-Blow)

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A time-delay fuse will have a relatively massive fuse element,

usually of low-melting-point alloy. As a result, these fuses can
provide large currents for relatively long periods without rupture.
They are widely used for circuits with large inrush currents, such as
motors, solenoids, and transformers.

Standard-Blow Fuse

These fuses are low-cost and generally of more conventional

construction, using copper elements, often in clear glass enclosures.
They can handle short-term high-current transients, and because of
their low cost, they are widely used. Very often the size is selected
for short-circuit protection only.

Very Fast Acting Fuses (HRC, or High Rupture Capacity,

Semiconductor Fuses)

These fuses are intended for the protection of semiconductor

devices. As such, they are required to give the minimum let-through
energy during an overload condition. Fuse elements will have little
mass and will often be surrounded by some form of filler. The
purpose of the filler is to conduct heat away from the fuse element
during long-term current stress to provide good long-term reliability,
and to quickly quench the arc when the fuse element melts under
fault conditions. For short-term high-current transients, the thermal
conductivity of the filler is relatively poor. This allows the fuse
element to reach melting temperature rapidly, with the minimum
energy input. Such fuses will clear very rapidly under transient
current loads.

Other important fuse properties, sometimes neglected, are the long-

term reliability and power loss. Low-cost fast-clearance fuses often
rely on a single strand of extremely thin wire. This wire is fragile and
is often sensitive to mechanical stress and vibration; in any event,
such fuse elements will deteriorate over the long term, even at
currents below the rated value. A typical operating life of 1000 h is
often quoted for this type of fuse at its rated current.

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The more expensive quartz sand-filled fuses will provide much

longer life, since the heat generated by the thin element is
conducted away under normal conditions. Also, the mechanical
degradation of the fuse element under vibration is not so rapid, as
the filling gives mechanical support.

Slow-blow fuses, on the other hand, are generally much more robust
and have longer working lives at their rated currents. However, these
fuses, with their high "let-through" energies, will not give very
effective protection to sensitive semiconductor circuits.

This brief description covers only a very few of the ingenious

methods that are used in modern fuse technology to obtain special
characteristics. It serves to illustrate the number of different
properties that fuses can exhibit, and perhaps will draw a little more
attention to the importance of correct fuse selection and
replacement.

4 SELECTING FUSES

Off-Line Switchmode Supplies

The initial fuse selection for off-line switching supplies should be

made as follows: For the line input fuse, study the turn-on
characteristics of the supply and the action of the inrush-limiting
circuitry at maximum and minimum input voltages and full current
limited load. Choose a standard- or slow-blow fuse that provides
sufficient current margin to give reliable operation and satisfy the
inrush requirements. Its continuous current rating should be low
enough to provide good protection in the event of a genuine failure.

However, for long fuse life, the current rating should not be too close
to the maximum rms equipment input current measured at minimum
input voltage and maximum load (perhaps 150% of I rms maximum).
Note: Use measured or calculated rms currents, and allow for the
power factor (approximately 0.6 for capacitor input filters) when
calculating rms currents.

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The voltage rating of the fuse must exceed at least the peak supply
voltage. This rating is important, as excessive arcing will take place
if the voltage rating is too low. Arcing can let through considerable
amounts of energy, and may result in explosive rupture of the fuse,
with a risk of fire in the equipment.

5 SCR CROWBAR FUSES

If SCR-type overvoltage protection is provided, it is often

supplemented by a series fuse.

This fuse should have an I^2 t rating considerably less (perhaps

60% less) than the SCR I^2 t rating, to ensure that the fuse will clear
before SCR failure. Of course, a fast-blow fuse should be selected in
this case. The user should understand that fuses degrade with age,
and there should be a periodic replacement policy. The failure of a
fuse in older equipment is not necessarily an indication that the
equipment has developed a fault (other than a tired fuse).

6 TRANSFORMER INPUT FUSES

The selection of fuses for 60-Hz transformer input supplies, such as

linear regulator sup plies, is not as straightforward as may have
been expected.

Very often inrush limiting is not provided in linear power supply

applications, and inrush currents can be large. Further, if grain-
oriented C cores or similar cores are used, there is a possibility of
partial core saturation during the first half cycle as a result of
magnetic memory of the previous operation. These effects must be
considered when selecting fuses. Slow-blow fuses may be
necessary.

It can be seen from the preceding discussion that the selection of

fuse rating and type for optimum protection and long life is a task to
be carried out with some care. For continued optimum protection,
the user must ensure that fuses are always replaced by others of the
same type and rating.

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