PROTECTIVE EQUIPMENT UPDATE From Cooper Power Systems, McGraw-Edison Protective Equipment Plant Date September 1988 Olean, New York Issue 5 TIN VS. SILVER FUSE LINKS - A COMPARISON For a number of years the controversial topic regarding the "best" mater: use in standard (single speed) fuse link eiements has existed. The two element materials in prevalent use have historically been silver and tin. (Special multi-element links having special characteristics for particular applications, such as the McGraw-Edison Type S and Type H links, also have been developed.) McGraw-Edison manufactures a wide variety of fuse link styles and ratings to suit virtually every possible overcurrent protection and coordination scheme being used today. Included in this line of fuse links are a number of different types and speeds, including both tin element and silver element designs. Experience and design testing has shown that -both tin and silver perform acceptably as fusible elements. However, each type does have advantages and disadvantages to consider when specifying fuse links for a particular application. Current Carrying Capability The critical performance aspect for any fuse link is its response to various current levels. The element material used in a given fuse link design can and will have a major impact on its current carrying performance. A fuse link is carefully designed, tested and constructed to insure that it melts (and Subsequently clears) as a result of an overcurrent condition on the system. The fusible element is precisely selected to ensure that this critical performance aspect is achieved and that the fuse link meets its published time current characteristic (TCC) curve. When comparing silver and tin element fuse links, it is important to understand the means in which each style reacts to steady state and overcurrent conditions. It is conmonly recognized that silver has a much higher melting temperature (960°C) than tin (231°C). For typical fuse link designs which meet the performance criteria for the Type K and Type T speeds (as descrited in ANSI/IEEE C37.42), a tin link will generally run at lower (cooler) operating temperatures than will the equivalent silver link subjected to the same set of operating conditions. This 1s due to the relatively high temperature needed to melt a silver fuse element. COOPER POWER SYSTEMS Post Office Box 388, Olean, MY 14760ANSI standards define that the melting current for a given K or T link rating must be 220% of the fuse link's amperage rating. As noted earlier, the melting temperature of a tin element is considerably lower than that of a silver element. When loaded to 150% of its current rating, the tin element K or T link runs relatively cool (typically well below 150°C). As a result, tin element K and T links can be rated to carry 150% of their nameplate current rating continuously. Some utilities utilize this capability to extend fuse link coordination. Due to the higher melting temperature of silver (960°C), subjecting a silver link to 150% of its nameplate current rating can result in serious consequences due to its high operating temperatures. The heating effects of tin and silver fuse links with various current levels applied are detailed in Figure 1. ° Tos ison a08 Comparative Mouting of Tin and Sliver EXI-MDM Lisks Figure 1 Element_Overheat The consequences of overloading a silver link above its rated current can be serious. Material such as bone fiber (the interrupting material used in cutout fuse tubes), bakelite, and the paper or fiber fuse link auxiliary tubes, can become scorched or burned at temperatures ranging from 150°C to 250°C. ‘High fuse link operating temperatures can also cause the cutout current exchanges to run hotter, possibly causing contact degradation due to overheating. Testing has been performed which verifies the extreme temperature buildup that will occur at the fusible element and in the cutout fuse tube as a result of overloading silver element fuse links. It has also been determined through testing that silver link designs that utilize a spiral element are especially prone to this type of condition. With this type of construction, the coiled element wire essentially becomes a small heater coil which causes this heat buildup to be concentrated in a confined area. A straight silver element configuration can allow for better heat dissipation and slightly better resistance to overheating. Page 2Ambient Temperature and Pre-Loading - Performance Effects The ability of a fuse link to perform in accordance with published TCC curves can be adversely affected by external factors, such as ambient temperatures and pre-loading. ANSI C37.40, (37.41 and (37.42 define the service conditions, definitions and test requirements for all standard fuse links. In ANST (37.91-1981, Section 12.1.4, it states that all tests shall be performed at an ambient temperature of 20-30°C, with no initial loading present. TCC tests are typically run at 25°C ambient to comply with this requirement. While these test conditions allow for consistent data collection and inter- pretation, they are not really representative of typical fuse link applications on utility systems. As noted earlier, the significant difference in melting temperatures of silver and tin element materials has corresponding effects on fuse link performance. Included in these effects are the actual fuse link melting and clearing charac- teristics when applied on a utility system compared to manufacturers’ published TCC curves. Tin element fuse links are generally more susceptible to perform- ance variation due to ambient temperature considerations than silver links due to the lower melting temperature of the element material. Figure 2 shows a representation of the temperature effects on fuse link performance for a typical current rating. Figure 2 Fuse link performance changes due to varying temperatures generally are not felt to be a major concern of utility customers for several reasons. In a given portion of a distribution system, the approximate ambient temperature for all the individual fuse links is generally felt to be within a few degrees. Pro- viding that all tin element or all silver element links are being used, each fuse link on a section of the utility system will be subject to an equivalent temperature de-rating, so that overall system performance is not compromised. In addition, the de-rating of tin element fuse link TC's is similar to the performance changes in oil circuit reclosers due to ambient temperature considerations Page 3