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16mm Copper Wire for Fuse. Fuse Time/Current Curve

10/08/2012 11:30 PM

Hello Gurus,

Does anybody have 16mm copper wire's (used for fuse) time/current curve ?

I am analysing circuits for arc flash and wonering what would be a fuse curve of 16mm copper wire.

The wire will certainly fuse and break the circuit reduce incident energy but at what level ?

I have general understanding that 16mm wire is good for ~80A normal current. What happens if 200A, 500A, 1000A, 5000A currents flows due to short circuit ? How quickly it will break the circuit. What is the function of Time and Current ?

Thanks,

Jack

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#1

Re: 16mm Copper wire for Fuse. Fuse time/current curve

10/08/2012 11:35 PM

I presume you mean 16mm2 rather than 16mm....

Either way, it might start a fire before breaking the circuit.

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#2
In reply to #1

Re: 16mm Copper wire for Fuse. Fuse time/current curve

10/08/2012 11:44 PM

5,000 amps in 16mm2 will fry things quickly.

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#4
In reply to #2

Re: 16mm Copper wire for Fuse. Fuse time/current curve

10/08/2012 11:53 PM

Hi Lyn,

I understand it would too.

I just want to know what is the time-current curve for fusing.

Thanks,

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#3
In reply to #1

Re: 16mm Copper wire for Fuse. Fuse time/current curve

10/08/2012 11:52 PM

Hi Tornado,

Yes, I mean 16mm2.

I know it will start fire, explotion and damage to surrounding equipments.

I just want to know the time current curve .

Thanks,

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#5

Re: 16mm Copper wire for Fuse. Fuse time/current curve

10/09/2012 12:30 AM

If it's fuse wire, then it's probably not copper.

The general fuse current response times are outlined in the SAE standards and from mempory it's something like this.

100% rating forever

150% overload for 2 mins.

300% overload for 10 secs.

500% overload less than 1 sec.

Unlike a circuit breaker with faster response times.

You will of course need to know what the initial rating for that conductor is.

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#8
In reply to #5

Re: 16mm Copper wire for Fuse. Fuse time/current curve

10/09/2012 1:06 AM

Hi,

Its not a fuse wire.

We are after the Pure copper wire's fusing characteristic.

Thanks,

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#10
In reply to #8

Re: 16mm Copper wire for Fuse. Fuse time/current curve

10/09/2012 3:12 AM

Then something is going on that is not contained within the relevant national electrical code.

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#6

Re: 16mm Copper wire for Fuse. Fuse time/current curve

10/09/2012 12:37 AM

Don't know if this will help, but

The Book Reference Data for Radio Engineers 5th edition

AWG B & S #7, 0.1443 Inch diameter copper wire fuses at 561 ampere.

AWG B & S #6, 0.1620 Inch diameter copper wire fuses at 668 ampere.

I believe this is for bare copper wire in air.

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#9
In reply to #6

Re: 16mm Copper wire for Fuse. Fuse time/current curve

10/09/2012 1:07 AM

Hi,

Thanks for that.

Would you know time at the perticular current ?

Thanks,

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#7

Re: 16mm Copper wire for Fuse. Fuse time/current curve

10/09/2012 12:45 AM

You could look up the melting point and specific heat of copper, and from that compute how many watt-seconds it takes to heat the copper that far. Your curve will come out more or less as a hyperbola like y = k/(x-x0).

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#11

Re: 16mm Copper wire for Fuse. Fuse time/current curve

10/09/2012 6:56 AM
I should employ the IEEE 80 calculation method for grounding conductor.
In IEEE 80 ch. 11.3 Conductor sizing factors [Formula 37]
I=Amm2*sqrt(TCAP*10^(-4)/(ts*alphar*ror)*ln((Ko+Tm)/(Ko+Ta))
Where
I is the rms current in kA
Amm2 is the conductor cross section in mm2
Tm is the maximum allowable temperature in oC
Ta is the ambient temperature in oC
Tr is the reference temperature for material constants in oC
alphao is the thermal coefficient of resistivity at 0 oC in 1/oC.
alphar is the thermal coefficient of resistivity at reference temperature Tr in 1/oC
ror is the resistivity of the ground conductor at reference temperature Tr in Ohm-cm
Ko 1/ao or (1/ar) - Tr in oC
ts is the duration of current in s
TCAP is the thermal capacity per unit volume [from Table 1], in J/(cm3.°C)
Replacing:
A=alphar*ror*10^4/TCAP
B=Ln((Ko+Tm)/(Ko+Ta))
I=Amm2*sqrt(B/A/ts)
For copper conductor ror=1.724;alphar=0.00393;Ko=234.5;TCAP=3.422 .Reference temperature 20oC
A=0.00393*1.724*10^4/3.422=19.8
The copper fusing temperature it is 1083 oC.From ambient 40oC
B=Ln((234.5+1083)/(234.5+40))=1.5685
If Amm2=16 for ts=1 I=4.5 kA .For ts=0.1 sec I=14.2 kA.
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#12

Re: 16mm Copper Wire for Fuse. Fuse Time/Current Curve

10/09/2012 9:33 AM

The answer you seek is in the Onderdonk Equation which gives the fusing time of a copper wire in free air as a function time and current. Here's a handy calculator for it:

http://www.cirris.com/testing/resistance/fuse.html

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#13

Re: 16mm Copper Wire for Fuse. Fuse Time/Current Curve

10/09/2012 10:47 AM

I

I did not know this formula was introduced by W. H. Preece and I. M. Onderdonk as no mention it is in IEEE-80 or IEEE 837 .
Sverak was the last known using this in Grounding Theory. It appear also in IEC 724 .
This formula takes into consideration only adiabatic heating phenomenon. Some of the heat nevertheless will spread in the surrounding
atmosphere and from the end contact. IEC 949 states some indication how to calculate the short-circuit current value for insulated cable
considered non-adiabatic heating calculation.
The maximum short-circuit value calculated for adiabatic heating has to be multiplied by a factor of 3-10%[1.03-1.1]depending on
short-circuit clearing time[1.1 for 1 sec 1.03 for 0.1 sec].

EC 724

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#14
In reply to #13

Re: 16mm Copper Wire for Fuse. Fuse Time/Current Curve

10/09/2012 11:48 AM

You are correct. The Onderdonk equation is an empirical formula and uses assumptions that are not necessarily applicable to every situation. It is best used in situations where the current is applied in a step function so that the heat transfer to the surrounding environment is minimized due to the short rise time. When the current is ramped then heat transfer can become an issue, requiring consideration of such things as ambient conditions, horizontal or vertical orientation, presence of insulation, enclosures, etc.

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#15

Re: 16mm Copper Wire for Fuse. Fuse Time/Current Curve

10/09/2012 3:26 PM

Also try an internet search for arc flash as this particular application is quite different from standard fuse and protection characteristics and is very site and fault specific (hence the failure characteristices of copper wire cannot be relied upon like those of fuses with controlled curves).

Don't forget to take into account the up-steam protection from the fault. Remember, the upstream protection curves will dictate the maximum let through energy and duration while the maximum short circuit current will be dictated by the transformer and line impedance and resistance.

This may not give you the true let through current and energy but it will give you an idea of the maximum and hence worst case arc fault that could occur.

Jack - Sells arc flash safety apparel (among other things).

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#16

Re: 16mm Copper Wire for Fuse. Fuse Time/Current Curve

10/10/2012 10:40 AM
Actually the above formula could be easy obtained theoretically.
The heat produced in a conductor by current passing through it is R*I^2*t for a definite time t or R*I^2*dt for an infinite small time interval.
If we'll neglect SKIN and PROXIMITY effect the conductor resistance will increase only with the temperature
Rt=Rr*[1+alpha*(T-Tr)]
Rr=ror*length[m]/Amm2 [ ror units has to be =ohm.mm^2/m=ohm.cm/100]
Since ror it is in ohm.cm Rr=ror/100*length[m]/Amm2
Let's say alpha

will get the same value from Tr up to Tm.

R*I^2*dt- heat produced in the conductor produce the conductor heat energy rising by:
TCAP*Vol*dT- conductor infinite small temperature difference rising.
Vol=conductor volume=Amm2*length[m]=[cm^3]
In an adiabatic heating no energy dissipation will be considered.
I^2*ror/100*length[m]/Amm2*(1+alpha*T-alpha*Ti)*dt=TCAP*Amm2*length*dT
I^2**dt=TCAP*(Amm2)^2/ror*10^2*dT/(1+alpha*T-alpha*Ti)
integrating both parts we'll get:
I^2*ts=TCAP*(Amm2)^2/ror/alpha*10^2*LN[(1-alpha*Tr+alpha*Tm)/(1-alpha*Tr+alpha*Ta)]
LN[(1-alpha*Tr+alpha*Tm)/(1-alpha*Tr+alpha*Ta)]=LN[((1-alpha*Tr)/alpha+Tm)/(1-alpha*Tr)/alpha+Ta)]
Ko=(1-alpha*Tr)/alpha
For copper conductor Tr=20oC alpha=0.00393
Ko=(1-0.00393*Tr)/0.00393=234.4529
I=Amm2*SQRT(TCAP*10^2/ror/alpha/ts*LN((Ko+Tm)/(Ko+Ta))) A
If we need kA we have to divide by 10^4 instead multiplying by 10^2 under the sqrt.
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#18
In reply to #16

Re: 16mm Copper Wire for Fuse. Fuse Time/Current Curve

10/10/2012 11:56 PM

Hi 7anoter4,

Thanks for the formula. It gives us approximation of the time/current.

Obviously upstream protection and current limitation should be considered in the equation.

Thanks,

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#20
In reply to #18

Re: 16mm Copper Wire for Fuse. Fuse Time/Current Curve

01/24/2013 7:43 AM

If current limitation is present, then the current will be limited to the 100% full load point, and therefore the copper wire will never melt.

There is no point in having the upstream protection rating higher than the 100% full load point of this copper wire, otherwise the melting of the copper wire will take place at a lower current than the upstream protection rating, rendering the upstream protection irrelevant and superfluous.

The undercurrent of this thread is quite abstruse, as it's outside the safety envelope of national electrical standards such as British Standard 7671. Fire indemnity insurance Risk Assessors and Loss Adjusters do understand these things, and having an installation that is not installed to the relevant standard gives them an opportunity of walking away from the damage caused, laughing all the way to the bank.

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#17

Re: 16mm Copper Wire for Fuse. Fuse Time/Current Curve

10/10/2012 6:39 PM

Jacklyb,

I was looking at this question earlier this week! Discussed this with an electrical engineer and looked at the arc flash calculations for my system (it ended with a #12 AWG wire approx. 15-feet or 4.5-meter long tapped from much larger conductors on an 800A breaker) with a short circuit current of about 2.5 to 5 kA. That upstream breaker had a 3300A instantaneous trip and the commercial software calculated a clearing time for that breaker of about 140 sec. I protested that the Onderdonk fusing time for this wire was approx. 0.03 sec. He said that he had never heard of a person using the melting of the wire to change the characteristics of the circuit and thus change the permissible time for arc flash calculations of incident energy.

We are still trading emails regarding this situation, because all the arc flash calculating software I know of assumes a steady state in the equipment exposed to the arc flash (no allowance for vaporized or melted materials, etc.) That appears to be where we get into the subjective analysis and the extent to which an engineer or other person is willing to go beyond the very conservative results of a calculation.

--John M.

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#19
In reply to #17

Re: 16mm Copper Wire for Fuse. Fuse Time/Current Curve

10/11/2012 12:14 AM

Hi Jmueller,

In fact, the purpose of the question was to investigate/study minimum load/circuit beyond which it should be low arcflash risk to be analysed and calculated for individual circuit.

i.e If a circuit has fuse rating less than 125A (400V) then the incident energy will be low enough to cause fatal injury. The exercise minimises the time to analyse low energy circuits and unnecessary inconvenience of arcflash risk where not necessary. Generally in most industry anything below 125A fuse circuits has vast network of feeders.

Good designed circuits with 16mm2 copper cables should have fuses installed at upstream of the cables to protect the cables.

The QUESTION is what other industry set as their minimum arcflash philosophy.

Thanks,

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