TITLE: BLOWN FUSE INDICATOR ON AC LOAD

PRESENTED BY:.
ADMISSION NO:

CENTER NAME:
COURSE : DIPLOMA IN ELECTRICAL
ENGINEERING
CODE:
INDEX NO:

SUPERVISOR: MR. AMBROSE BARASA

SERIES:

PRESENTED TO: KENYA NATIONAL EXAMINATION

COUNCIL IN PARTIAL FULFILLMENT FOR
THE AWARD OF DIPLOMA CERTIFICATE
ELECTRICAL ENGINEERING
DECLARATION

DECLARATION BY THE STUDENT

I declare officially that this is my original work free from any kind of plagiarism and that this
work has not been produced elsewhere.

NAME:

Signature ----------------------------

Date ------------------------------------

DECLARATION BY SUPERVISOR

This is work is provided by my consent as the Trainer in Matili Technical Training Institute.

NAME

Signature----------------------

Date ----------------------------

i
DEDICATION
I dedicate this work to my parents who have always supported my dreams and aspirations, and
given me all the financial and moral support to this stage.

ii
ACKNOWLEDGEMENTS
I wish to acknowledge the following people who assisted me in ensuring that the business plan
project was successfully done:

My Trade project Trainer for his support and advice during the period of preparing the
project.
Mr. Adongo, My HOD for his moral support and contributions towards the writing of this
project.
Above all I thank God for giving me the strength to come this far.

iii
ABSTRACT

It is very important to correct faults in the electrical system of a car or motorcycle or another,
as soon as possible. If you don’t know that a fuse is blown, you may run into trouble when
the problem is harder to solve. For example at night or far from an Electrical workshop. A
blown fuse indicator circuit warns us, by lighting an LED, when there is a problem in an
electrical installation protected by the fuse.

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 Table of Contents
DECLARATION......................................................................................................................................i
DEDICATION.........................................................................................................................................ii
ACKNOWLEDGEMENTS....................................................................................................................iii
ABSTRACT...........................................................................................................................................iv
CHAPTER ONE..............................................................................................................................................1
1.0 INTRODUCTION.............................................................................................................................1
1.1 BACKGROUND OF THE PROJECT...............................................................................................1
1.2 PURPOSE OF THE PROJECT................................................................................................................1
1.3 AIM OF THE PROJECT.........................................................................................................................1
1.4 OBJECTIVE OF THE PROJECT..............................................................................................................2
1.5 LIMITATION OF THE PROJECT............................................................................................................2
1.6 ADVANTAGES OF THE PROJECT.........................................................................................................2
1.7 APPLICATION OF THE PROJECT..........................................................................................................3
1.8 PROJECT ORGANIZATION...................................................................................................................4
CHAPTER TWO.............................................................................................................................................5
2.0 LITERATURE REVIEW..........................................................................................................................5
2.1 OVERVIEW OF THE STUDY................................................................................................................5
2.1.0 TYPES OF FUSES AND THEIR APPLICATIONS................................................................................5
2.1.1 DC FUSES....................................................................................................................................5
2.1.2 A.C FUSES....................................................................................................................................6
2.1.3 CARTRIDGE TYPE FUSE...............................................................................................................6
2.1.4 D-TYPE FUSE...............................................................................................................................6
2.1.5 LINK-TYPE FUSE...........................................................................................................................7
2.1.6 BLADE FUSE................................................................................................................................8
2.1.7 Bolt down fuse............................................................................................................................8
2.1.8 RE-WIREABLE FUSE....................................................................................................................8
2.1.9 STRIKER FUSE..............................................................................................................................9
2.1.10 DROPOUT FUSE.......................................................................................................................10
2.1.11 SWITCH FUSE..........................................................................................................................10

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 2.1.12 HIGH VOLTAGE FUSE...............................................................................................................10
2.1.13 CARTRIDGE TYPE HV HRC FUSE...............................................................................................10
2.1.14 LIQUID TYPE HV HRC FUSE......................................................................................................11
2.1.14 EXPULSION TYPE HV HRC FUSE..............................................................................................12
2.2 REVIEW OF THE RELATED STUDY.....................................................................................................13
2.2.1 WHAT HAPPENS WHEN A FUSE BLOWS...................................................................................13
CHAPTER THREE........................................................................................................................................15
3.0 CONSTRUCTION METHODOLOGY....................................................................................................15
3.1 BASICS OF THE SYSTEM....................................................................................................................15
3.2 BLOCK DIAGRAM.............................................................................................................................15
3.3 SYSTEM OPERATION........................................................................................................................16
3.4 CIRCUIT DIAGRAM...........................................................................................................................16
3.5 CIRCUIT DESCRIPTION......................................................................................................................17
3.6 DESCRIPTION OF THE COMPONENTS USED.....................................................................................17
3.7 Construction & Working.................................................................................................................17
CHAPTER FOUR..........................................................................................................................................18
4.0 TESTING AND RESULTS....................................................................................................................18
4.1 CONSTRUCTION PROCEDURES AND TESTING..................................................................................18
4.2 INSTALLATION OF THE COMPLETE DESIGN......................................................................................19
4.3 ASSEMBLING OF SECTIONS..............................................................................................................19
4.4 TESTING OF SYSTEM OPERATIONS...................................................................................................19
4.5 COST ANALYSIS................................................................................................................................19
CHAPTER FIVE............................................................................................................................................21
5.1 CONCLUSION...................................................................................................................................21
5.2 RECOMMENDATION........................................................................................................................21
REFERENCES..............................................................................................................................................22

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 CHAPTER ONE

1.0 INTRODUCTION

1.1 BACKGROUND OF THE PROJECT

With increase in invention and improvement of technology, we are realizing a constant surge
of new intricate electrical and electronic designs. Automation has been fostered in every
field . Automation is basically the delegation of human control function to technical
equipments. Modern process control systems are used in industrial automations for
flexibility, modularity and reliability, employing state of the art technology. Basically,
since circuit protection is among the major considerations, it is prudent to monitor the circuit
protection devices for they are integral parts in which case if they fail then the whole system
will fail to perform its intended function.

1.2 PURPOSE OF THE PROJECT

After a good research, I realized that most electronic gadgets for instance the computer
power supply system and digital television power supply systems whose fuses failed, lacked
automatic systems which could help the repairing technicians. This is the reason behind this
project. To come up with a solution to solve this challenge at hand.

1.3 AIM OF THE PROJECT

Blown Fuse Indicator will help us to identify fault quickly, We use different types of Circuits
and application board, here the most burning device will be the fuse element. We can’t
completely avoid this fuse element because it protects the circuit elements from high current
draw and voltage surges.

1
1.4 OBJECTIVE OF THE PROJECT

The main objective is designing and fabricating a working blown fuse indicator that can be
used in simple as well complex electrical circuits .specifically:

i. Designing an electrical circuit of a blown fuse indicator

ii. Fabricating the electrical design of the blown fuse indicator
iii. Testing the blown fuse indicator

1.5 LIMITATION OF THE PROJECT

This project is mainly concentrated on fuses as circuit protective devices which have some
disadvantages as listed below:

i. Fuses are slow compared to circuit breakers which belong to another class of circuit
protective devices.

ii. When fuses operate they produce heat. The heat produced is not productive hence
they waste energy.

iii. Fuses do not respond to high voltages it only cares about current flowing and is not
likely to melt and save the house in case of a direct lightning strike

iv. Do not give protection against voltage surges.

v. They need to be replaced every time. Circuit breakers as circuit protection devices can
be used multiple times

1.6 ADVANTAGES OF THE PROJECT

Fuse is the cheapest protection device in electrical circuit against short circuits and
overloading of circuits. Fuse is a metal wire or thin metal strip which has the property of low
melting point which is inserted into the electrical circuit as protective device.

Fuse provides protection against excessive currents which can flow in circuit during short
circuits. Under normal working condition the current flowing through the circuit is within

2
safe limits but when fault occurs such as short circuit occurs or when load more than circuit
capacity is connected to it, current exceeds the limiting value results in fuse wire gets heated
up, melts and break the current. Thus fuse protects the machine or electrical equipment
against the excessive currents.

Time for blowing out of fuse depends on the magnitude of the excessive current. Larger the
current more rapidly the fuse blown off. Thus fuse have inverse time characteristics. Such
characteristics is desirable for protective gear.

Fuses are used on low and high voltage circuits of moderate to high capacity where frequent
operation is not expected. Fuse is employed for protection of distribution transformers, small
and medium size motors, lighting circuits, branch circuits of distribution lines, in industrial
plants and commercial buildings. A blown fuse indicator will serve to assist in faster problem
identification during the troubleshooting process.

1.7 APPLICATION OF THE PROJECT

Electrical or Electronic Fuses are one of the main components in almost all electrical or
electronic circuits, systems and applications. Some of the commonly known applications of
Fuses are mentioned below. The blown fuse indicator can be integrated in the following
applications

i. Home Electrical Wiring

ii. Air Conditioners
iii. Washing Machines,
iv. Televisions and, Music Systems
v. Motor Starters
vi. Mobile Phones
vii. Laptops

3
 viii. Power Adapters
ix. Cameras
x. Printers, Scanners and Photocopiers
xi. All Automobile (Cars, Bikes, Trucks, Buses, etc.)
xii. All Electronic Devices (Hard Disks, DVD Writers, DVD Players, etc.)
xiii. Gaming Consoles

1.8 PROJECT ORGANIZATION

Project conceptualization

Data collection

Literature review

Design of project

Fabrication of the project

Testing of project

4
 CHAPTER TWO

2.0 LITERATURE REVIEW

2.1 OVERVIEW OF THE STUDY

2.1.0 TYPES OF FUSES AND THEIR APPLICATIONS
Many types of fuses are there that interrupt an over-current and breaks the circuit by melting
the fuse element. They are mainly divided into two types, AC fuse, and DC fuse.
Furthermore, fuses are classified into different types depending on voltage and construction.
They are:

2.1.1 DC FUSES

DC fuses produce an arc that are difficult to stop than AC arcs because there are no zero
current flows in the circuit. For reducing the DC fuse arcing the electrodes are placed at more
distance due to which the size of the fuse increases as compared to AC fuse.

5
2.1.2 A.C FUSES

Low voltage fuses are very common in electrical systems and they come in different shapes
and designs. Low voltage fuses have a voltage rating of less than or equal to 1,500V.

2.1.3 CARTRIDGE TYPE FUSE

Figure 2: Cartridge-type-fuse
Figure 1: Cartridge-type-fuse construction

Cartridge fuse consists of the heat-resisting ceramic body enclosed by a metal cap at both
ends. The filling material such as chalk, plaster of Paris, quartz or marble dust surrounds the
body space which acts as an arc quenching and cooling medium. Often, they are widely used
in industries, agricultural areas and residential purposes such as fuse panels, air conditioning,
pumps, and home appliances.

2.1.4 D-TYPE FUSE

Figure 3: D-type fuse

Figure 4: Construction

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It consists of an adapter ring, cartridge, base, and cap. The fuse base is connected to the fuse cap

and the cartridge is kept inside the fuse cap through the adapter ring. The circuit gets completed

when the tip of the cartridge makes contact with the conductor.

2.1.5 LINK-TYPE FUSE

Figure 5: Link type fuse

Link-type cartridge fuses are also known as High Rupturing Capacity fuses (HRC). HRC

fuse has a high breaking capacity. It has two metal ends on both sides. The Filling of the fuse

with powdered pure quartz acts as an arc extinguishing agent. The fuse element uses silver or

copper for its construction.

The fuse element carries the short circuit current for a long period of time. During this time,

an uncertain fault will melt and open the circuit. The chemical reaction between a silver

vapor and the filling powder forms a high resistance which helps in quenching the arc.

7
2.1.6 BLADE FUSE

Figure 6: Blade fuse

The Blade fuse are also known as spade or plug-in fuse. Automotive OEMs use this fuse for
vehicle circuit protection and withstand high temperatures.

2.1.7 Bolt down fuse

Figure 7: Bold down fuse

Bolt down fuse are special-purpose ones suitable for diesel vehicles and not appropriate for
automotive trucks.

2.1.8 RE-WIREABLE FUSE

Re-wirable fuse is also known as a Kit-Kat fuse. It is a simple and cheapest form of a fuse. This

fuse is suitable for domestic wiring for e.g. in houses. Moreover, when the fuse blows out, it is

easy to replace and reuse. It consists of a fuse base and a fuse carrier. The construction of fuse

element in the fuse carrier uses tinned copper, lead or aluminum and porcelain for the base.

8
The base has two terminals for incoming and outgoing supply. When a fault occurs, the fuse

element blows out and interrupt the circuit. The blown-out fuse can be replaced by a new one.

The main advantage of this type of fuse is, it is re-wireable but the disadvantage is less reliable.

Figure 8: Re-wirable fuse

2.1.9 STRIKER FUSE

This type of fuse has a mechanical indicator or striker pin that protrudes through the fuse cap

upon operation of the fuse. This provides visual identification of a blown fuse and acts as a

trigger for external devices. It can be used for short circuit protection of medium voltage motors.

Figure 9:
Striker fuse

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2.1.10 DROPOUT FUSE

Drop out fuse is an expulsion type fuse to protect the transformers. When the fuse element melts,
it falls due to gravity, hence providing additional isolation.

Figure 10 : Dropout Fuse

2.1.11 SWITCH FUSE

Switch fuse is used for low and medium voltages circuit. They can safely break depending
upon rating currents of the order of 3 times the load current.

2.1.12 HIGH VOLTAGE FUSE

Transformers and Power systems use High voltage fuses. The fuse element uses material
such as copper, silver or tin. The rating voltage for high voltage fuse is above 1500V and
upto 138000V. They are classified into three types: Cartridge type HRC fuse, Liquid type
HRC fuse, Expulsion type HRC fuse.

2.1.13 CARTRIDGE TYPE HV HRC FUSE

This cartridge fuse is similar to low voltage HRC fuse with some extra features. The fuse
wounds in the shape of a helix or use two fuse elements in parallel to prevent the corona
effect at the higher voltages. HV HRC fuses are available with a rating of 33kV with a
rupturing capacity of 8700A.

10
Figure 11: Cartridge Type HV HRC Fuse

One of the fuse element has low resistance and the other has high resistance. Therefore, a low

resistance wire carries the normal current which blows out and reduces the short circuit current

during a fault condition.

2.1.14 LIQUID TYPE HV HRC FUSE

A liquid fuse (for high currents) consists of a glass tube filled with carbon tetrachloride and

sealed with brass caps at both ends. The fuse wire covers sealing at one end and fixing by strong

phosphor bronze spiral spring at another end of the glass tube. The liquid acts as an arc

extinguishing medium. The fuse blows out when the current exceeds the maximum limit. Liquid

type HRC fuse protects transformer and circuit breakers. They withstand current upto 100A on

systems up to 132kV.

Figure 12: Liquid Type HV HRC Fuse

11
2.1.14 EXPULSION TYPE HV HRC FUSE

This type of fuse is an escapable fuse in which the expulsion effect of the gases produced by
internal arcing results in current interruption. The fuse link chamber contains boric acid.
Therefore, an internal arcing helps in the protection of feeders and transformers.

FIGURE 3: EXPULSION TYPE HV HRC FUSE

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2.2 REVIEW OF THE RELATED STUDY

2.2.1 WHAT HAPPENS WHEN A FUSE BLOWS

There are two conditions that can cause a fuse to blow. First, and most commonly, when too
many lights or plug-in appliances draw power from the circuit, it can overload the capacity
of the fuse and cause the metal ribbon inside the fuse to melt through. The result is that all
lights, outlets, and appliances powered by the circuit will go dead suddenly. When you
examine the fuse, you will likely notice that the metal ribbon located behind the glass
window is melted through, or you will notice a fog or cloudiness in the window, indicating a
very sudden melting of the ribbon. The immediate solution here is to replace the fuse with
one of the same size. Longer term, though, you will need to move some plug-in appliances
into other circuits to avoid another overload and another blown fuse. Appliances that heat
(such as toasters or clothes irons) or those with motors (such as vacuum cleaners) are
especially prone to causing overloads, since their power draw is fairly large, especially when
they first startup.

Another cause of a blown fuse occurs when a hot wire somewhere in the system touches
either the grounding pathway or a neutral wire. This is what is known as a short circuit, and
it typically occurs because of loose wire connections, damaged wires somewhere along the
circuit, or an internal wiring problem in some appliance plugged into the circuit. A mis-wired
lamp, for example, can cause a short circuit and blown fuse if it is plugged into an outlet. Or
wires that have been eaten through by rodents in walls can cause a hot wire to touch the
grounding path or a neutral wire. The immediate symptom is the same as for an overload -
the metal ribbon inside the fuse burns through and all lights and fixtures along the circuit go
dead. But in the case of a short circuit, merely replacing the fuse will likely cause the new
one to blow immediately - unless the short circuit has been fixed.

13
Diagnosing the location of a short circuit can take patience. Because many short circuits
occur in plug-in lamps or appliances, start by unplugging every lamp and appliance, then
replace the burned out fuse. If the new fuse holds, it is likely that the wiring problem was in
one of the lamps or appliances you unplugged. If not, then the problem exists somewhere in
the circuit wiring itself. You can visually inspect each outlet, wall switch, and light fixture
for loose connections, but there is a good chance that you will need to call in a professional
electrician to locate and fix the problem.

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 CHAPTER THREE

3.0 CONSTRUCTION METHODOLOGY

3.1 BASICS OF THE SYSTEM

Safety fuses or fusible links see wide use in modern electronic equipment to protect the load and
the power supply - especially batteries - against short circuits and excessive load current. Fuses
are inexpensive and simple, and a wide range of parts is available. However, you must replace
them when they blow, and, when they do, you need an indicating circuit that warns you about its
failure, especially when the fuse body is ceramic or sand-filled for improved protection against
arcing.

3.2 BLOCK DIAGRAM

SOURCE OF POWER

FUSE BLOWN FUSE INDICATOR

CONNECTED PARALLEL TO FUSE

LOAD

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3.3 SYSTEM OPERATION

The blown fuse indicator is connected in parallel with the fuse. When the fuse is good all current
travels through the fuse. When fuse is blown current flow through the blown fuse indicator and it
is illuminated.

3.4 CIRCUIT DIAGRAM

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3.5 CIRCUIT DESCRIPTION

The blown fuse indicator is to be connected in parallel with the fuse. The system is connected in
such a way that it indicates a blown fuse with or without the load. The LEDs and resistors are
connected in series and this combination is connected in parallel to the existing fuse. When the
fuse is intact, it offers a low resistance and so the voltage drop across it will be not sufficient
enough to glow the LED. When the fuse is blown off, it is equivalent to infinite resistance and so
the entire power supply will drop across the resistor LED series combination and makes the LED
glow. The resistance R1 and R2 are used to limit the current through LEDs.

3.6 DESCRIPTION OF THE COMPONENTS USED.

The following materials shall be required in the fabrication of the design:

i. 4 Light Emitting Diodes

ii. 3 100 K ΩResistors
iii. Connecting Wires
iv. Capacitor2 µ F 400 v
v. PCB Board
vi. Solder .
vii. Soldering Gun
viii. Solder Sucker

3.7 Construction & Working

The Blown Fuse Indicator Circuit has Resistors and LEDs connected in series and then paralleled
with target fuse. When we apply AC supply to Load through this fuse and circuit setup, due to
the low Resistance in the Fuse wire current will easily flow through it and there is no current
flow through Resistor and LED hence the LED stays in OFF condition.

If the fuse blown for some reason then there is no current flow through open fuse, then here the
current flow occurs through Resistor and LED only, so the LED starts to glow (that is ON) by
the way it indicates the blown fuse.

17
 CHAPTER FOUR

4.0 TESTING AND RESULTS

4.1 CONSTRUCTION PROCEDURES AND TESTING

The circuit was designed on a PCB module to accommodate the following as per the circuit
diagram:

i. 4 Light Emitting Diodes

ii. 3 100 K ΩResistors
iii. Connecting Wires
iv. Capacitor2 µ F 400 v
v. PCB Board
vi. Solder .
vii. Soldering Gun
viii. Solder Sucker

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4.2 INSTALLATION OF THE COMPLETE DESIGN

At each stage of design and fabrication, tests were carried out to ensure that all the components
were installed as per the circuit specifications. Soldering of the components was done using a
soldering gun which was connected to the socket outlets while in the process of installation.

4.3 ASSEMBLING OF SECTIONS

After the installation of the components on the BCP, Connecting cables were connected to the
input of the circuit and then connected to the top plug that was to serve in connecting to the
source of power. The power supply unit of a system unit was also used as load on the blown fuse
indicator

4.4 TESTING OF SYSTEM OPERATIONS

During testing, the system was connected to a 240V AC mains supply and a 240V AC bulb
served as a load. Now, when the system was switched on, the bulb did light. To simulate the
blown fuse, the system was first switched off.

The fuse was then removed from the circuit. on switching on the bulb did not light yet two of the
LEDs did light thereby confirming that the system had been successively made. The power
supply unit of a system unit was also used as load on the blown fuse indicator.

4.5 Power consumption

The two resistors R1 and R2 will only be engaged when the fuse has blown.

The effective resistance of the circuit can be given by: R1 + R2 since they shall be in a series

connection.

R1 + R2=100 k Ω+ 100 k Ω=200 k Ω

240 V
current of the circuit ¿ =0.012 A
200 k Ω

Power=VI =240 V × 0.0012=0.288 Watts

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4.6 COST ANALYSIS
To achieve this project, several tasks needed to be performed which ranged from planning, data
collection and research, material collection and designing testing and finally the processing of
the write-up.

The summary of how the whole process was in terms of finances is included in the following
table of cost analysis.

OVERALL PROJECT COST

No. Description Quantity Unit Cost Total Cost

1 Data collection 1,000 1,000

2. Transport and fare 1,000 1,000

3. Project Design 2,000 2000

4. Project Write-up 2,500 5,500

TOTAL 5,500

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MATERIAL COST

NO. DESCRIPTION QUANTITY UNIT COST TOTAL COST (KSH)

1 Light Emitting Diodes 4 Pcs 50 200

2. 100 K ΩResistors 3 Pcs 50 150
3. Connecting Wires 2m 100 200

4. Capacitor2 µ F 400 v 2 Pcs 100 200

5. PCB Board 1 Pc 200 200
6. Solder . 0.5M 200 100
7. Soldering Gun 1 Pc 300 300
8. 1 Pc 200 200
Solder Sucker
TOTAL 1550

In addition, the cost of production or fabrication was KSh 450.

21
 CHAPTER FIVE

5.1 CONCLUSION

Troubleshooting of intricate electrical and electronic designs requires automation..

Automation being basically the delegation of human control function to technical
equipments. A blown fuse indicator serves as a simple automated sensor that can help.
Modern process control systems are used in industrial automations for flexibility,
modularity and reliability, employing state of the art technology. Since circuit
protection is among the major considerations, it is prudent to monitor the circuit protection
devices for they are integral parts in which case if they fail then the whole system will fail to
perform its intended function.

5.2 RECOMMENDATION
This project that was aimed at solving one of the common challenges was a success yet for

conveniences of use or application, i feel that in terms of size, it is very bulky and that room

for improvement on size is being recommended so that its application may find a wide scope

now that most of the inventions and designs are continually being minimalized in terms of

size.

22
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Power Magzine#67 • October / November 1998,pp.100.

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rectifier, Conference Record of the IEEE International Symposium on Electrical

Insulation, pp.514 –517.

Robless D B, and King R J (1992). A 1 kW unity-power - factor rectifier with isolation

and fault protection, Seventh Annual Applied Power Electronics Conference and

Exposition,pp. 541–548.

Salomonsson D, Soder L et al. (2009). Protection of low-voltage DC microgrids, IEEE

Transactions on Power Deliver y, vol.24 ,3,pp. 1045–1053.

Eui - Cheol N, In-Dong, K et al. (2001). An improved output short - circuit protection

for multilevel PWM rectifier, The 27th Annual Conference of the IEEE Industrial

Electronics Society, vol 2, pp. 909–914.

Galloway J H, and Buddingh P (2010). Protection of large power conversion equipment,

57 th Annual Petroleum and Chemical Industry Conference, Industry Applications

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Livint G,Chiriac G et al. (2005).Aspects regarding the hybrid electric vehicles architecture

and the management strategy for the energy flow, The 4th Management of

Technological Changes Conference (Chania), pp. 275–280.

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DC - DC converters study, Buletinul Institutului Politehnic Iaşi, vol LI(LV), pp.

217–224.

Chiriac G (2012). Thermal analysis of fuses with variable cross-section fuselinks, Electric

Power Systems Research, Vol 92, pp. 73– 80.

Cantemir L, Nituca C et al . (2011). Unconventional current collection from a contact line

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