Fuseology
Fuse Holders, Fuse Blocks, Power Distribution Blocks & Surge Suppression
Optima® Fuse Holders & Overcurrent Protection
Modules
Compact, full-featured modules that
deliver Type 2 coordinated protection,
with properly sized fuses. Available in a
broad range of combinations for
process control panel applications. Hold
Class CC and midget style fuses.
Fuse Blocks
Cooper Bussmann fuse blocks are available in a
wide range of sizes for power distribution, high
speed semi-conductor protection and electronic
applications. UL Listed, CSA® certified. Classes
H (K), R, T, J and CC fuses. Standard module
and pyramid styles available.
Optima Fuse Holder
Without Switch Data
Sheet No. 1102
Optima Overcurrent
Protection Module
Data Sheet No. 1109
Optima Fuse Holder
With Switch
Data Sheet No. 1103
CH Series Global Modular Fuse Holder
The new and improved ‘CH’ line
of Modular Fuse holders is
designed to accommodate a
multitude of fuses from around
the world, including North
American Class CC, Class J, and
Midget plus IEC Industrial
Cylindrical (Class gG and aM) in
four physical sizes: 8x32, 10x38,
14x51 and 22x58mm and Class
gR, aR HSF.
Key Features and Benefits:
• Multiple pole configurations
• Finger Safe protection
• Optional “open-fuse” indication
• 14x51 & 22x58 configurations
are available with optional microswitches for remote “open fuse” indication,
pre-breaking, and fuse presence.
• Self-extinguishable UL 94V0 rated polyester material
• Multi-phase connections available for ganging poles
Data Sheet Nos. 2143, 2144
Panel-Mount Fuse Holders
Shown here is a typical Cooper
Bussmann panel-mount fuse holder.
This HPS-RR holder is a rejection
type which accepts rejection type
branch circuit fuses such as the
Cooper Bussmann LP-CC, KTK-R
and FNQ-R.
Data Sheet No. 2113
Power Distribution Blocks
For industrial control panels, HVAC
and other control automation panel
applications. Available in 1, 2, or 3pole versions and a wide range of
input/output terminations. Includes
new line with high short-circuit
current ratings; makes it easy to
obtain high short-circuit current
ratings for panel assembly.
Data Sheet No. 1148, 1117
Safety J™ Fuse Holder for Class J Fuses
Compact and finger-safe design
that meets IP-20 requirements.
Fuse is removed/installed external
to circuit. Open fuse indication
available. Integral 35mm DIN Rail
adapter.
Data Sheet No. 1152
Sami™ Fuse Covers with Option/Open Fuse
Indication
Dead front protection, optional
open fuse indication. The Sami ™
fuse covers fit most fuses and
fuse blocks. Covers snap on in
seconds - no special wiring
required.
NEW — High
Short-Circuit
Current Ratings
Surge3™ Surge Suppression Devices
Overvoltage protection for
Industrial Electronics from
harmful transients. Smallest
package available and modular
design allows two choices of
protection, MOV or a patented
Diode configuration. Each
protection technology has its
value. Local and remote status
indication. Available in voltages
from 12Vdc – 240Vac
Data Sheet No. 9006
Data Sheet No. 1204
For Data Sheets: www.cooperbussmann.com
18
©2005 Cooper Bussmann
Conductors & Terminations
Application Considerations
• These excessive thermal conditions described above may cause
the device (block, switch, fuse, circuit breaker, etc.) insulating
system to deteriorate, which may result in a mechanical and/or
electrical breakdown. For instance, the excessive thermal
condition of a conductor termination of a circuit breaker can
degrade the insulating case material. Or a fuse block material
may carbonize due to the excessive thermal conditions over a
long time.
Normally, a fuse is mounted in a fuse clip or bolted to a metal surface. It is
important that the two surfaces (such as fuse to clip) are clean and mechanically tight so that there is minimal electrical resistance of this interface. If not,
this interface is a high resistance spot, which can lead to a hot spot. With a
fuse to clip application, the temperature rise from a poor clip can cause even
further deterioration of the clip tension. This results in the hot spot condition
getting worse.
The middle, line-side conductor to this disconnect became loose. The loose
connection created an excessive thermal condition that caused excessive damage to
the device termination, the middle conductor and the adjacent conductors.
Conductor & Termination Considerations
A fuse, as well as a circuit breaker, is part of a system where there are
electrical, mechanical and thermal considerations. All three of these are
interrelated. If there is too much electrical current for the circuit, the
components can overheat. If a conductor termination is not properly torqued,
the termination can be a “hot spot” and contribute excess heat. This additional
heat is detrimental to the integrity of the termination means, conductor
insulation and even the overcurrent protective device. If the conductor size is
too small for the circuit load or for how the fuse/termination or circuit
breaker/termination has been rated, the undersized conductor will be a source
of detrimental excess heat, which bleeds into the devices through the
terminals. This excess heat can cause integrity issues.
How important is the proper conductor size and proper termination methods?
Very! Many so called “nuisance” openings of overcurrent protective devices or
device failures can be traced to these root causes. Improper electrical
connections can result in fire or other damage to property and can cause
injury and death. If there are loose terminal connections, then:
• The conductor overheats and the conductor insulation may break
down. This can lead to a fault; typically line to ground. Or, if
conductors of different potential are touching, the insulation of
both may deteriorate and a phase-to-neutral or phase-to-phase
fault occurs.
• Arcing can occur between the conductor and lug. Since a poor
connection is not an overload or a short circuit, the overcurrent
protective device does not operate.
• The excessive thermal condition of the conductor termination
increases the temperature beyond the thermal rating of the fuse
clip material. The result is that the fuse clip can lose its spring
tension, which can result in a hot spot at the interface surface of
the fuse and clip.
©2005 Cooper Bussmann
The fuse clip on the right has excellent tension that provides a good
mechanical and electrical interface (low resistance) between the fuse and clip.
The clip on the left experienced excessive thermal conditions due to an
improper conductor termination or undersized conductor. As a result, the clip
lost its tension. Consequently, the mechanical and electrical interface between
the fuse and clip was not adequate which further accelerated the unfavorable
thermal condition.
Some Causes of Loose Terminal Connections
Below are some possible causes for loose terminal connections for various
termination methods and possible causes of excessive heating of the
overcurrent protective device / termination / conductor system:
1. The conductor gauge and type of conductor, copper or aluminum, must be within the
connector’s specifications. The terminals for a fuse block, terminal block, switch,
circuit breaker, etc. are rated to accept specific conductor type(s) and size(s). If the
conductor is too large or too small for the connector, a poor connection results, and
issues may arise. Additionally, it must be verified that the terminal is suitable for
aluminum conductor, copper conductor, or both. Usually the termination means is
rated for acceptable conductor type(s) and range of conductor sizes; this is
evidenced by the ratings being marked on the device (block, switch, circuit breaker,
etc.) or specified on the data sheet.
2. The connector is not torqued to the manufacturer’s recommendation. Conductors
loosen as they expand and contract with changes in temperature due to equipment
running and not running. If the connections are not torqued appropriately, loose
connections may result. For a mechanical screw, nut, bolt or box lug type
connection, follow the manufacturer’s recommended torque. Typically the specified
torque for a connector is marked on the device. For a specific connector, the
specified torque may be different for different wire sizes.
3. The conductor is not crimped appropriately. A poor crimp could be between the
conductor and a ring terminal. It could be between the conductor and the quick
connect terminal. Or, it could be between the conductor and an in-line device. If
using a compression connection, use the manufacturer’s recommended crimp tool
with the proper location and number of crimps.
55
Conductors & Terminations
Application Considerations
4. The quick connect terminal is not seated properly. If the male-female connections are
not fully seated, a hot spot may be created.
5. The quick connect terminal is being used beyond its amp rating. Quick connects
typically have limited continuous current ratings that must not be exceeded. Typical
maximum ratings possible for a quick connect are 16 or 20A (some are less); this is
based on a proper conductor size, too. If the quick connect is used beyond its amp
rating, excessive temperature will result which can degrade the quick connect’s
tension properties and further overheating issues result.
6. The conductor is not properly soldered to a solder terminal. Again, if there is not a
good connection between the two, a hot spot will be created.
7. The terminal is only rated to accept one conductor, but multiple conductors are being
used. Again, the product specifications must be checked to see if the terminal is
rated for dual conductors. If the product is not marked suitable for dual conductors,
then only one conductor can be used for this termination. Inserting too many
conductors will cause a poor connection, which can result in heat or other problems.
Other important aspects in the electrical and thermal relationship for circuit
components in a circuit are the conductor size, conductor rated ampacity, the
conductor insulation temperature rating and the permissible connector device
conductor temperature limits. Conductors have specified maximum ampacities
that are based on many variables including the size of the conductor and its
insulation temperature rating. The NEC® establishes the allowable ampacity of
conductors for various variables and applications. In addition, there are some
overriding requirements in the NEC® and product standards that dictate the
ampacity of conductors when connected to terminals. For instance, the
ampacity for a conductor with 90°C insulation is generally greater than the
ampacity of a conductor of the same size but with 60°C insulation. However,
the greater ampacity of a conductor with 90°C insulation is not always
permitted to be used due to limitations of the terminal temperature rating
and/or the requirements of the NEC®. (Reference 110.14 in the NEC® for
specific requirements.) However, there are some simple rules to follow for circuits of 100A and less. These simple rules generally should be followed
because these are the norms for the device component product standards and
performance evaluation to these standards for fuses, blocks, disconnects,
holders, circuit breakers, etc.
Simple rules for 100 amps and less:
1. Use 60°C rated conductors [110.14(C)(1)(a)(1)]. This assumes all terminations are
rated for 60°C rated conductors.
2. Higher temperature rated conductors can be used, but the ampacity of these
conductors must be as if they are 60°C rated conductors. In other words, even if a
90°C conductor is used, it has to be rated for ampacity as if it were a 60°C
conductor [110.14(C)(1)(a)(2)].
For instance, assume an ampacity of 60A is needed in a circuit that has terminations
that are rated for 60°C conductors. If a 90°C conductor is to be used, what is the
minimum conductor size required?
Wire Size
60°C Ampacity
90°C Ampacity
6 AWG
55
75
4 AWG
70
95
The answer is 4 AWG, 90°C conductor. A 6 AWG, 90°C conductor has an ampacity
of 75 amps per (NEC® Table 310.16); but this ampacity can not be used for a 60°C
termination. For this circuit, if a 90°C, 6 AWG conductor is evaluated, the ampacity
of this conductor must be according to the 60°C conductor ampacity, which is 55A.
Ampacities are from NEC® Table 310.16.
4. For motors with design letters B, C or D, conductors with insulation rating of 75°C of
higher are permitted as long as the ampacity of the conductors is not greater than
the 75°C rating [110.14(C)(1)(a)(4)].
5. If a conductor is run between two devices that have terminals rated at two different
temperatures, the rules above must be observed that correlate to the terminal with
the lowest temperature rating.
For circuits greater than 100A, use conductors with at least a 75°C insulation
rating at their 75°C ampacity rating.
So why would anyone ever want to use a conductor with a 90°C or a 105°C
rating if they can’t be applied at their ampacity ratings for those temperatures?
The answer lies in the fact that those higher ampacity ratings can be utilized
when derating due to ambient conditions or due to exceeding more than 3
current carrying conductors in a raceway.
Example (ampacity and derating tables next page)
Circuit ampacity required: 60 amps
Ambient: 45°C
60°C terminal
75°C terminal
Conductor size and insulation rating?
Assume that an ampacity of 60A is needed in a circuit with a 75°C termination
at one end and a 60°C termination at the other end, where the ambient is
45°C. First, since one termination temperature rating is higher than the other,
the lowest one must be used, which is 60°C. The first choice might be a 4
AWG TW conductor with an ampacity of 70A at 60°C. However, in the NEC®
the Correction Factors table at the bottom of conductor ampacity Table 310.16
reveals that the 70A ampacity must be derated, due to the 45°C ambient, by a
factor of 0.71. This yields a new ampacity of 49.7, which is less than the
required 60. This is where a conductor with a higher temperature rating
becomes useful. A 4 AWG THHN conductor has a 90°C ampacity of 95A.
Again, looking at the table at the bottom of Table 310.16, a factor of .87 must
be used, due to the 45°C ambient. This yields a new ampacity of 82.65, which
is adequate for the required 60A ampacity.
Could a 6 AWG THHN conductor be used in this application? Its 90°C
ampacity is 75A. Using the factor of 0.87 for the 45°C ambient gives a new
ampacity of 65.25, which seems adequate for a required ampacity of 60A.
However, a 6 AWG conductor of any insulation rating could never be used in
this application because the 60°C terminal requires that the smallest amount
of copper is a 4 AWG for a 60A ampacity (simple rule 2 in previous
paragraphs). The amount of copper associated with a 4 AWG conductor is
required to bleed the right amount of heat away from the terminal. The use of
less copper won’t bleed enough heat away, and therefore overheating
problems could result.
3. Conductors with higher temperature ratings can be used at their rated ampacities if
the terminations of the circuit devices are rated for the higher temperature rated conductor [110.14(C)(1)(a)(3)]. However, the industry norm is that most devices rated
100A or less, such as blocks, disconnects and circuit breakers, have 60°C or 75°C
rated terminations.
56
©2005 Cooper Bussmann
Conductors & Terminations
Application Considerations
Allowable Ampacities
The table below shows the allowable ampacities of insulated copper
conductors rated 0 through 2000 volts, 60°C through 90°C, not more than
three current-carrying conductors in a raceway, cable, or earth (directly
buried), based on ambient of 30°C (86°F) (data taken from NEC® Table
310.16). The note for 14, 12, and 10 AWG conductors is a very important note
that limits the protection of these conductors.
Conductor
Size AWG
Ampacity For Temperature Rated
Copper Conductors (NEC® Table 310.16)
60°C
75°C
90°C
14*
20*
20*
25*
12*
25*
25*
30*
10*
30*
35*
40*
8
40
50
55
6
55
65
75
4
70
85
95
3
85
100
110
2
95
115
130
1
110
130
150
*See NEC® 240.4(D) which essentially limits (with several exceptions) the
overcurrent protection of copper conductors to the following ratings after any
correction factors have been applied for ambient temperature or number of
conductors: 14 AWG - 15A, 12 AWG - 20A, 10 AWG - 30A. Depending on the
circumstances of a specific application, the ampacity determined due to the
correction factors may be less than the values in Table 310.16. In those cases,
the lower value is the ampacity that must be observed. For instance, a 75°C,
10AWG in 50°C ambient would have a derating factor of 0.75, which results in
an ampacity of 26.25 (35A x 0.75). So in this case, the ampacity would be
26.25. Since 26.25 is not a standard size fuse per NEC® 240.6, NEC®
240.4(B) would allow the next standard fuse, which is a 30A fuse. The 30A
fuse is in compliance with 240.4(D). In a 35°C ambient, the correcting factor
for this same conductor is 0.94, so the new ampacity is 32.9A (35A x 0.94).
However, a 35A fuse can not be utilized because NEC® 240.4(D) limits the
protection to 30A.
Conductor Ampacity Correction
Factors For Ambient Temperatures
Conduit Fill Derating
Also, conductor ampacity must be derated when there are more than three
current-carrying conductors in a raceway or cable per NEC® 310.15(B)(2).
There are several exceptions; the derating factors are:
# Of CurrentCarrying
Conductors
4–6
7–9
10 – 20
21 – 30
31 – 40
41 & greater
% Values in NEC® Ampacity Tables
310.16 to 310.19 As Adjusted for
Ambient Temperature if Necessary
80
70
50
45
40
35
Termination Ratings
As discussed above, terminations have a temperature rating that must be
observed and this has implications on permissible conductor temperature
rating and ampacity. Shown below are three common termination ratings and
the rules. Remember, from the example above, the conductor ampacity may
also have to be derated due to ambient, conduit fill or other reasons.
60°C
Can use 60°C, 75°C, 90°C or higher temperature
rated conductor, but the ampacity of the conductor
must be based as if conductor is rated 60°C.
75°C
Can use 75°C, 90°C or higher temperature rated
conductor, but the ampacity of the conductor must be
based as if conductor is rated 75°C. A 60°C
conductor not permitted to be used.
60°C/75°C Dual temperature rated termination. Can use either
60°C conductors at 60°C ampacity or 75°C
conductors at 75°C ampacity. If 90°C or higher temperature rated conductor is used, the ampacity of the
conductor must be based as if conductor is rated
75°C.
Ambient Derating
Conductor allowable ampacities must be derated when in temperature
ambient greater than 30°C. The correction factors for the conductor allowable
ampacities in NEC® Table 310.16.are below.
Ambient
Temp. °C
For ambient other than 30°C, multiply conductor allowable
ampacities by factors below (NEC® Table 310.16)
Ambient
Temp. °F
60°C
75°C
90°C
21-25
1.08
1.05
1.04
70-77
26-30
1.00
1.00
1.00
78-86
31-35
0.91
0.94
0.96
87-95
36-40
0.82
0.88
0.91
96-104
41-45
0.71
0.82
0.87
105-113
46-50
0.58
0.75
0.82
114-122
51-55
0.41
0.67
0.76
123-131
56-60
–
0.58
0.71
132-140
61-70
–
0.33
0.58
141-158
71-80
–
–
0.41
159-176
©2005 Cooper Bussmann
57
Devices for Motor Circuits
Fuse Holders As listed to UL 512
When used with a motor disconnecting means and
properly sized branch circuit fuses, fuse holders
may provide main, feeder, branch circuit, motor,
motor circuit, and group motor protection. They
cannot be used alone as a motor disconnecting
means to meet NEC® 430.109, nor can they be
used alone as a motor controller (On-Off function)
to meet NEC® Article 430, Part VII.
Allowed Uses:
• Motor Controller
• “At the Motor” Disconnect if marked “Suitable as motor Disconnect” and
located between the motor branch circuit short-circuit and ground fault
protective device and the motor.
Identification
Motor Switches/Manual motor controllers as
listed to UL508 will contain a marking near the
agency symbol. This marking should read
manual motor controller or an abbreviation such
as Man. Mtr. Cntlr. Manual motor controllers
listed for use as a motor disconnecting means
will be marked “Suitable as Motor Disconnect.”
Identification
Fuse holders as listed
to UL 512 will contain a marking near the agency
listing symbol. This marking should read Listed
Fuse Holder.
Disconnect Switches-Fused and Non-Fused As listed
To UL 98
These are disconnect switches
from 30 through 6000 amps, that
may be used on service
equipment, panelboards,
switchboards, industrial control
equipment, motor control centers,
motor branch circuits, etc. These
switches may be used as a motor
disconnecting means to meet
NEC® 430.109. They may also be
used as a motor controller (on-off
function) to meet NEC® article 430, Part VII, and may be used as both a motor
disconnecting means and a motor controller (NEC® 430.111).
Allowed Uses:
• Motor Branch Circuit and “at the motor” Disconnecting Means
• Motor Controller
Identification
Disconnect switches as listed to
UL98 will contain a marking near the
agency symbol. This marking should
read "Listed Misc. Sw."
Motor Switches (Manual Motor Controllers)
As listed To UL 508
These switches may be used as a
motor controller (On-Off function)
to meet NEC® Article 430 Part VII.
As motor controllers, they have
creepage and clearance distances
that are less than those required
by UL 98. As a result, they cannot
be used as a motor disconnecting
means to meet NEC® 430.109. If the device is listed as a “manual motor controller” and is additionally marked “Suitable as Motor Disconnect” it shall be
permitted to serve as a motor disconnecting means if it is located between the
final motor branch-circuit short-circuit and ground-fault protective device and
the motor. This marking and listing is optional, so a review of the device markings will be required if intended to be used for this purpose.
128
Pullout Switches As Listed To UL 1429
These are switches from 30 through 200
amps at 600V or less. Pullout switches
with horsepower ratings are suitable for
motor disconnecting means to meet
NEC® 430.109, as motor controllers to
meet NEC® Article 430 Part VII (if rated
100Hp or less), and in general use for
panelboards, switchboards, etc. They
may be used as both a motor
disconnecting means and a motor controller to meet NEC® 430.111. Pullout
switches with amp ratings only
(no Hp ratings) are suitable for general use only, not motor circuits. If they are
marked “Motor circuit pullout switch” they may be used only in a motor circuit.
When used with properly sized branch circuit fuses, pullout switches may be
used for motor, motor circuit, and group motor protection.
Allowed Uses:
• Motor Branch Circuit and “at the motor” Disconnecting Means
• Motor Controller
Identification
Pullout switches as listed to UL1429 will contain a
marking near the agency symbol. This marking
should read Listed Pullout Switch.
Molded Case Switches As listed to UL 489
These switches are very similar to molded case thermal magnetic circuit
breakers except that they have no thermal overload protection. They may or
may not be equipped with a “magnetic” instantaneous trip as a self-protect
mechanism. They may be used on service equipment, panelboards,
switchboards, industrial control equipment, motor control centers, motor
branch circuits, etc. They are suitable for use as a motor circuit disconnect per
NEC® 430.109. They may be used as a motor controller (On-Off function) to
meet NEC® Article 430 Part VII, and as both a motor disconnecting means
and motor controller to meet NEC® 430.111.
Allowed Uses:
• Motor Branch Circuit and “at the motor” Disconnecting Means
• Motor Controller
Identification
Molded Case Switches as listed to UL489 will contain a marking near the
agency listing symbol. This marking should read Listed Molded Case Switch.
©2005 Cooper Bussmann