PROTECTIVE EQUIPMENT UPDATE From Cooper Power Systems, Components & Protective Equipment April 1992 Pewaukee, Wisconsin DISTRIBUTION TRANSFORMER OVERCURRENT PROTECTION - DEVELOPING A FUSING SCHEDULE, Introduction Giventhe numberof distribution transformers onaparticular power system andthe relatively few ratings used, protection engineers rely on fusing tables, or what we call recommended fusing schedules, to selectthe fuse ratings for their transformers. These fusing schedules are developed by manufacturers and/or protection engineers andare used by the operations personnelto determine the fuse neededfora new distribution transformer orto replace ‘a damaged fuse on an existing transformer. These fusing schedules are developed by taking into ‘account transformer charactersticssuchas ulloadcurrent, transformerdamage curve, and magnetizingand cold load inrush currents. Also, the fuse characteristics are taken into account in the form of continuous current carrying ability and, in some cases, lightning surge withstand capabilty NOTE: The transformer overload protection criteria addressed here is intended for distribution transformers protected by fuses (expulsion or current limiting) located Outside of the transformer tank (not in direct contact with the transformer cil). Underoil transformer fusing is not addressed here, TRANSFORMER FUSING RATIO (One key element in selecting the useratingsfortransformer, protection is the fusing ratio Fusing Ratio (F.R,) is defined as follows: Fuse Current Carrying Capacity FR. = “Transformer Full Load Current The fuse current carying capacity can be determined by ‘wo different methods: Method 1 uses the manufacturers published continuous ‘current capacity. coofer Method 2 uses the minimum melt current at 300 seconds from the published time-current characteristic curve. Each method results in a different fusing ratio for a given transtormerfuse link combination. Table | shows the continuous current carying capacity of various fuses made by Cooper Power Systems. TABLE |: Continuous Current Carrying Capacity of Cooper Power Systems Fuses at 25°C: Fuse Type | Current Carying Capacity (Amps) K,T-Tin [1.5 x Current Rating K Silver D-Link NX Current Rating xi! 1.35 x Current Rating LX 1.35 x Current Rating ‘As an example, consider a single phase, 50 kVA, 7.62 kV transformer with a 10 amp K-tin fuse link: Transformer Full Load Current = 50/7.62 = 6.56 amps Euse Current Carrying Capacity: Method 1: 10K Link = 1.5x 10. 15 amps Method 2: 10K Link Min. Melt Currant @ 300 sec. = 21 amps using Ratio: Method 1; 15A6.S6A = 2.29 Method 2: 210/6.56A «3.20 ‘The significance of the fusing ratio is that it provides an indication of how the transformer is protected. A high fusing ratio implies: More transformer failures on overloads Increased overload allowance tor transformer Increased service continuity Fewer fuses damaged by lightning surges Fewer fuses damaged on inrush Less expenditures on fuses, 1045 Hickory Street, Pewaukee, Wisconsin 53072‘A low fusing ratio implies: More fuses damaged by lightning surges More fuses damaged on inrush Increased expenditures on fuses Fewer transformers damaged by overloads Decreased service continuity ‘Since transformer and {use ratings are discrete values, the fusing ratio is usually specified as a range and is a key indication on how much overload is allowed for the transformer. Typical ranges are 1.5 -2.5 and 2.0-3.0. if the available fuse fora given transformer rating causes the {using ratio to be higher than the higher end of the range, another means of overload protection should be provided such as a secondary breaker. ‘TRANSFORMER DAMAGE CURVE A detailed explanation of the transformer damage curve canbe foundin Appendix |. In reference to the transformer damage curve, two things should be kept in mind: 1) the transformer damage curve is not a definite curve; itis a loss-of- ie indicator, and 2) tis generally accepted thal the fuse minimum melt (not the maximum clear) should be faster than the transformer damage curve, MAGNETIZING INRUSH CURRENTS ‘Another concem to address in developing the fusing sschedule's the magnetizing and cold-toad inrush currents. These currents are dependent on the transformers full load current and a multiplier based on tests and field experience. Forpoletype transformers protected by in-air ‘uses, the values typically used are: 2xl, @ 100seconds Cold-Load Inrush 3xl, @ 10seconds Cold-Load Inush 40x, @ 1 second Cold-toad Inrush 12x, @ 1 second Magnetizing Inrush 25xl, @ 01 second Magnetizing Inrush ‘The most ctitcal point for most types of expulsion fuses is the 12x@ .1 second. Inssome cases, such as the D-Link fuse, the 2 x @ 100 seconds point is the most critical due to the high surge withstand capabilty (thus requiring the TCC to be shifted tothe right for high current values) FUSING SCHEDULE ‘Appendix II (R240-30-6) shows the fusing schedule for distribution transformers protected with Cooper Power ‘Systems’ D-Linktuse. Thetusing ratiousedwascalculated Using Method 2 (the current carrying ability is determined from the 300 second point on the fuse minimum melt curve). For example, Appendix Il recommends a 4 amp D-Link fuse for a single-phase, 25kVA, 7.62kV transformer. (py = 25/7.62 = 3.28 amps). Figure 1 shows the time/ current plots for the 4 amp D-Link fuse with the inrush and transformer damage curves. The fusing ratio of the 4 amp D-Link fuse with this transformer is 2.36 based on Method 2. This is within the 200 - 300% rated load used to develop the schedule. It should be noted that the minimum melt curve of the 4 amp D-Link fuse does not intersect the transformer damage curve. Figure 2 showsthe TCC’ forthe same transformerbutwith ‘a5 amp D-Link fuse. This fuse rating was selected using Method 1 andwas obtained fromthe fusing schedule inthe fuse brochure, Bulletin 90016. Note that the fuse minimum melt curve intersects the transformer damage curve atthe 9.8 amp, 300 sec. point. The using ratio for this combination is 2.28, again based on Method 1 This example shows that different fuse rating recommendations may result basedon the methodusedio calculate the fusing ratio. CONCLUSION There Is not a preferred method for determining fuse ratings for cistibution transformers. The fusing schedule included here isto be used as a guide. ttis the protection engineer who will determine the fuse ratings based on his/ her knowledge, experience and the protection criteria adopted by histher company. The fusing ratio is an excellent indicator of ransformer protection, given hat the Criteria followed are fully understood.1000 , Jeo a aaMnGe CUE | | TART 6 or [ Al MI oo 1 1 1000 0400 cvs Figure 1 Damage Curve for a 10, 25kVA, 7.62kV Transformer with 4 Amp D Link 1000 100 \ - roel 1 " E 1 oo L |_ 0.010 1 0 ‘00 000 «10000 cuveent Figure 2 Damage Curve for a 1, 25kVA, 7.62kV Transsormer with 5 Amp D LinkBulltn 91027 Apel 1992 {© 1992 Cooper Power Systems Fila Soction 240-30* Appendix Attachment to Bulletin 91027 ‘TRANSFORMER DAMAGE CURVE ‘Overthe years, protection engineers have been using the transformer “damage” curve as a guide to determine the level of protection of a transformer. This curve is composed of time-current points that combine both the thermal and mechanical withstand capabiities of power transformers. The term damage is in quotes because this curve is not definite, that is, exposing a transformer to 2 given through fault current for atime that will exceed the level shown in the curve will not cause immediate failure of the transformer. This damage curve is more of alife-reduction indicator than anything else. ANSI Standard C57.12.00 defines four categories of transformers based on the kVA ratings for both 39 and 1@ units: ‘Galecory AQKVA BOKVA 1 5-500 15-500 " 501 - 1,667 501 - 5,000 uw 1,668 - 10,000 5,001 - 30,000 v Above 10,000 ‘Above 30,000 Each category has its own damage curve (or set of curves) as shown in Figures A-t through A-4, Pole-type distribution transformers are usually 500 KVA or smaller and, therefore, we willonly be concerned here with the damage curve for Category | transformers, ‘As canbe seen in Figure A-1, the damage curva is expressed in per unit current (1 per-unitis equal to 100% transformer full load current). To determine the exact curve for a given transformer rating, all numbers in the X-axis should be ‘multiplied by the transformer full load current. The full oad current is determined as follows: I= KVASEV,., Single Phase I=KVA/Y3KV,,, Three Phase For a 1@, 50 KVA, 7.62 kV transformer, |, = 6.56 amps and its damage curve will be as shown in Figure A-5. cooker 1045 Hickory Street, Pewaukee, Wisconsin 53072 1Appendix Attachment to Bulletin’91027 * os Figure A-1 Category | Transformers a \ wl \ I | ¥ i ' Figure A-2 Category Il TransformersAppendix Auachment to Bulletin 91027 =e ee | tt [eee jure A-3 Category Ill Transformers \ Cc ‘ c “i j *F Figure A-4 Category IV TransformersAppendix Attachment to Bulletin¥1027 * 00 a0 oo rr er ee) cae Figure A-S Damage Curve for a 19, 50kVA, 7.62kV Transformer