Low Voltage Systems Protective Fuses in Commercial Industrial Applications To BS IEC Standard

LOW VOLTAGE SYSTEMS & PROTECTIVE FUSES IN COMMERCIAL & INDUSTRIAL SYSTEMS TO BS & IEC STANDARDS
(S.R. Javed Ahmed)
A Fuse is an important Protective device used to automatically disconnect a live circuit when a predetermined value of current & or time of predetermined current is exceeded. The disconnection mean by fuse is based on the applicable Protection philosophies. Fuses are available in AC & DC circuits from extra low voltages to High Voltages. A Circuit Breaker (CB) also does similar type of function as a fuse. Unlike a CB, fuse is self-destructive which requires replacement after it disconnects a circuit. Some CBs also perform switching function with or without current flowing in the circuit. A hybrid device is a fused-disconnect switch which has a fuse associated with a load/no-load disconnecting switch (may be group operated or single pole type). Some fuses provide additional function such as operation indication (dropout, burnt mark, a plunger etc), driving an aux contact to close, limiting the peak current etc. General Protection Philosophies in LV System Based on the application & philosophies, various Protection means are applied. The following are general groups on which the Protection systems are designed: i. Prevention of Electric Shocks Direct Contact Indirect Contact Dealing with Electric shocks due to Direct Contact: Preventing a current from passing through the human body or any livestock Limiting the current which can pass through the human body or any livestock to lower than the Shock current Dealing with Electric shocks due to Indirect Contact: In dealing with protection against indirect contact under single fault conditions, regulations permits the two methods given above for Direct contact and additionally Automatic disconnection of supply in a determined time on occurrence of a fault which is likely to cause a current to flow through the body in contact with exposed conductive
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parts (where the value of current is equal to or greater than the shock current). ii. Prevention against Thermal effects Preventing ignition of flammable material due to heat or arc Preventing burns to human or livestock Preventing degradation or impairment of the Equipment Prevention against Over Current Preventing injury to human or livestock or equipment due to thermal as well as electromechanical stresses due to Overcurrent. Prevention against Fault Current Preventing the conductors or any other part carrying Short-circuit from attaining temperature greater than its design value and Electrodynamic-withstand levels (peak current).
iii.
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v. Prevention against Over Voltages Preventing the damage to property, equipment, human or livestock due to: Over voltages which cause faults between circuits supplied at different voltages Over voltages which arise due to switching & atmospheric actions. 1. Fuse Identification Various Fuses exist in Electric circuits. Our first task is to identify the Fuse application and type. There are general three types of Fuses found in an Electric circuit categorized as: Miniature Fuses
Glass
Ceramic
These Fuses are identified as type: FF (Ultra Rapid) F or QA or QB (Fast Blow) M or MD (Medium Blow) T or SB (Slow Blow) TT (Ultra Slow) Bottle Fuses
Bottle Fuse These Fuses are identified as type: DIAZED 500V Fuses, D1 (E16), D11 (E27), D111 (E33) NEOZED 380V Fuses, D01 (E14), D02 (E18) SILAZED Ultra Rapid Fuses, D11 (E27), D111 (E33) Industrial Fuses These Fuses are identified as type: aR or gR or uR (Ultra Rapid) gL or gG (General Line) gM (Motor rated general Line) aM (Motor rated) gF or gTF (Transformer, Cable Protection) gB (Mining Fuses)
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Knife Blade Fuses
Wedge Fuse
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Typical Street lighting Fuse
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House Service Cut-out Fuse 2. Fuse Current Rating THE AMPERE RATING Generally, a Fuse current rating shall not be less than the full load rating of the circuit it is protecting. Over loads or Over Currents if occur frequently will degrade the fuse performance and hence there shall be clear idea of overloads which occur frequently or infrequently. Over currents typically occur in Motor circuits, charging (energizing) a reactive equipment like a Capacitor, Shunt Reactor, Transformer etc. Over loads occur due to diversity in loads (based on max load, connected load or contingency loads, increased loads, process jams, mechanical failures etc). some Overcurrents or Overloads are requires the circuits to be disconnected, while others may be transient requiring fuses to ride through them (in coordination with some other protective device upstream or downstream). Obviously, upstream device operation before the fuse is designed to enhance interruption capability. Two general types are used which are type gG & gM. Type gG Fuses: i. For application based on Protection of the cables against Short circuit: Type gG fuses have characteristics to protect the cables against short circuit current & Overload conditions when they are selected with a current rating (1N) is less than or equal to the current rating of the cable (1z). ii. For Motor circuit application where the Motor Starter will provide Overload protection.
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In these applications, Fuses provide only against short circuit current. Fuses for Transformers: Fuses for Transformer primary side protection typically shall have current rating of at least twice the nominal Transformer primary current. Fuses for Fluorescent lighting circuits: Fuse current ratings normally should be twice the numbers of lights to be simultaneously switched. Fuses for PF correction Capacitor circuits: Fuse current ratings normally should be at least 1.5 times the Capacitor circuit rated current. Fuses for Motor circuits: Motors starting currents are typically larger than their rated (full load) current. Starting current depends on the type of Motor starting means implemented. Motor starter Manufacturers recommend coordination based on IEC 60947-4-1. Type2 coordination with type gG & gM fuses shall be made as per BS88 or IEC 60269. Most of gG type fuses can be used for Motor circuits but Fuses (& associated holders) shall be much larger rated current than Motor Full load current (FLA or motor rated current) to meet the Motor Starting curves. Type gM fuses however, are rated same as the Motor FLA and fit same holders as normal gG fuses. gM fuses extend the utilization of standard equipment. With Motor run-up time of less than 5s, the Table below indicates recommended gG & gM fuses ratings (with Motor duty infrequent no more than twice per hour). Next larger size shall be used for demanding applications.
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Fuse rating based on Conductor sizes: The maximum fuse that can be used depends on the Cable type using an appropriate K factor. For PVC insulated cables factor K = 115 (Thermoplastic 70C) and for XLPE insulated cables K = 143 (Thermosetting 90C). The following table gives ratings for Fuses for popular Copper conductors (with thermoplastic & thermosetting insulations):
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BS 88 Industrial Fuses:
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Protection against Electric Shocks: Max Disconnecting time: For a TN System, a disconnecting time not exceeding 5s is permitted in a distribution circuit. Maximum Earth Loop Impedance: The maximum values of earth loop impedance (Zs) for typical gG 240V fuses to BS88: Parts 2 & 6 are:
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Fuse derating due to ambient Temperature: Typically current derating of 0.5% per C above an ambient of 35C is recommended The rated Continuous Temperature: Cable circuits are having a typical conductor temperatures rating of 70C for PVC insulation & 90C for XLPE based insulation. Fuses, switches and other circuits are thus, genera lly, based on 70C as allowable conductor temperature. The rated Short Circuit Temperature of Cables: Typically 250C is SC temperature ratings for LV cables. Standard Interruption current withstand rating of Fuses:
80kA for 415Vac systems 40kA for dc applications 50kA for 240V systems Fuse to fuse Coordination ratio: All fuses to BS88: Parts 2 & 6 will give a coordination ratio of 2:1. Meaning an upstream fuse rated for 200A will coordinate with a downstrean 100A rated fuse. For most practical situations some Manufacturers recommend a ratio of 1.6:1 Fuse Current & Energy Limitation: The pre-arcing It values limits shall be as specified in BS88. Common BS 88 HRC Fuses by various manufacturers
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3. Protection Philosophy Various philosophies are applicable based on the Protection requirement . vi. Prevention of Electric Shocks Electricity regulations mentions of dealing with two types of Electric Shocks: Direct Contact Indirect Contact Dealing with Electric shocks due to Direct Contact: Preventing a current from passing through the human body or any livestock
Limiting the current which can pass through the human body or any livestock to lower than the Shock current Dealing with Electric shocks due to Indirect Contact: In dealing with protection against indirect contact under single fault conditions, Electricity regulatione permits the two methods given above for Direct contact and additionally Automatic disconnection of supply in a determined time on occurrence of a fault which is likely to cause a current to flow through the body in contact with exposed conductive parts (where the value of current is equal to or greater than the shock current). 4. Load Diversity A ratio of Maximum demand to the Connected load defines load diversity of the system. This ratio is always less than 1. It is fairly easy to calculate the connected load by adding all loads. A system designed to meet the connected load meets all the safety requirements but is sometimes fairly expensive. Maximum demand evaluation required engineering knowledge and judgment on part of the designer. Lighting loads: Max demands of lighting system load can be calculated based on the luminaries connected in terms of watts. Below recommendation is based on the IEE Guidance:
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Below recommendation is based on the IEE Guidance Heating loads: Max demands of lighting system load can be calculated based on the connected load in terms of watts (normally at unity power factor).
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Cookers loads:
Water heating loads:
Motor loads:
Conventional circuit loads:
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Socket loads (other than conventional):
5. System earthing Value of external earth loop impedance & the magnitude of prospective earth fault current depends on type of earthing used. In case of domestic & commercial applications, regulation puts the consumer to be fully responsible for earthing at his location (not the supplier of Electricity). Five basic earthing arrangements embodied in systems are identified as: TN-C, TN-S, TN-C-S, TT & IT.
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Figure 4.1: TN-C System
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Figure 4.2: TN-S system
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Figure 4.3: TN-C-S system
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Figure 4.4: TT System
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Figure 4.5: IT system
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EARTHED EQUIPOTENTIAL BONDING AND AUTOMATIC DISCONNECTION OF SUPPLY
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6. Mm
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NOTATIONS USED IN WIRING BS/IEC STANDARDS
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Low Voltage Systems Protective Fuses in Commercial Industrial Applications To BS IEC Standard

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Low Voltage Systems Protective Fuses in Commercial Industrial Applications To BS IEC Standard

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LOW VOLTAGE SYSTEMS & PROTECTIVE FUSES IN COMMERCIAL & INDUSTRIAL SYSTEMS TO BS & IEC STANDARDS

(S.R. Javed Ahmed)

Knife Blade Fuses

Typical Street lighting Fuse

Water heating loads:

Conventional circuit loads:

Socket loads (other than conventional):

Figure 4.1: TN-C System

Figure 4.2: TN-S system

Figure 4.3: TN-C-S system

Figure 4.4: TT System

Figure 4.5: IT system

EARTHED EQUIPOTENTIAL BONDING AND AUTOMATIC DISCONNECTION OF SUPPLY

NOTATIONS USED IN WIRING BS/IEC STANDARDS

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