Fuses for PV applications

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 1. What a fuse ?

Fuse:

Conduct normal current.

Short-circuit and/or overload protection device

Installed in series in the circuit loop involved

Protects equipment and people from potential effects
of OVERCURRENT like overheating / fire / external
arc.

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Safety :

The metallic element inside the fuse melts directly
upon the fault current effect without any
intermediate mechanism, sensor, …

The arc extinction is totally enclosed no emission

of gas, flames, arcs or melted material

The arc flash energy is drastically reduced when

the peak current is limited by a fuse

A new safe element to replaced the melted fuse.

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 2. PV panel data example :

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 3. Why a fuse ?

To protect modules against fault

currents (reverse current)

1, 2 & 3 strings in parallel : fuses Exemple N=4

are not necessary.

Maximum number of strings in
parallel without electrical
protection:
N ≤ ( 1+ IRM / ISCSTC ) *

IRM : Maximum reverse current

module
3ISC ISC ISC ISC

ISCSTC : Short Circuit Current F F F F

STC : Standard Test Conditions

(25°C, 1000W/m², spectre AM 1,5)

* Guide UTE C 15-712-1

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 Protect cables against short-circuits along the cable

Groupe de chaînes 1 Groupe de chaînes 2 Groupe de chaînes Nc

ISC
groupe
(Nc-1)xISC ISC ISC
groupe groupe groupe

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 4. How to choose the right fuse ?
Rated voltage : UNfuse ≥ UOCmax *

UOCmax = maximum open circuit voltage.

It’s the maximum voltage delivery by panels in series at the minimal
temperature of use when the circuit is open.

practically, UOCmax = 1,2x UOCSTC
STC : conditions standard (25°C, 1000W/m², spectre AM 1,5)

Inverter are working at constant power, see diagram UPS MPPT (maximum power point
tracker) and U/I curve.

* Guide UTE C 15-712-1

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 Nature of current : Direct Current

Fuses have to be designed and tested for DC applications.

When a fault occurs in a DC circuit, the absence of natural voltage zero

crossing makes the interruption of DC faults more difficult than the
interruption of AC faults as only the arc overvoltage generated by fuse will
force the current to decrease to zero.

The correct interruption depends on three parameters:

the value of the DC voltage,

the value of the ratio L/R (time constant) of the fault path

the magnitude of prospective fault current.

The possible low level of overload to be eliminated in photovoltaic equipment

is a very arduous condition for a fuse! Consequently, special photovoltaic
fuses designed and tested for PV applications have to be used to ensure
people safety and photovoltaic circuit protection.

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 Breaking range and utilization category : gPV

Breaking range « g » : full range breaking capacity, including

low current fault due to overload.

Utilization category « PV» : specially designed and tested for

the protection of Photovoltaics applications and specifically for
modules according to the standard IEC 60269-6 (october 2010)

aM aR gG gR

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 Rated current of fuse : IN ≥ 1,4xISC *

The life time of the fuse is mainly depending of :

Ambient temperature in the box
Cycles of current : day/night, clouds, …

The life time is longer when the ratio IN/ISC high

“1,4” has to be considered as the minimum derating value
(for PV applications)
This derating have to be increase if :
Ta (ambient temperature) > 60°C
use in confined space (like a box)
Sunshine upper than 1000W/m²

* Guide UTE C 15-712-1

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 5. Requirements of IEC 60269-6
Low-voltage fuses – Supplementary requirements for fuse-links for the
protection of solar photovoltaic energy systems

Nominal voltage Un ≤ 1500V cc

Breaking range and utilization category : gPV

Breaking capacity : > 10kA

Tested under Direct Current

Tested of nominal current under

3000 cycling

Tested after 50 cycling of temperature (-40°C/+90°C )

Tested at In at the maximum ambient temperature (50°C)

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 6. Requirements of UL 2579
Fuses for photovoltaic systems

Nominal voltage Un ≤ 1500V cc

Breaking range and utilization category : gPV

Classification : Non-Renewable, Not Current-Limiting

Breaking capacity : > 10kA

Night to Day Climate Cycle Simulation : Electrical performance

verified after repeated thermal cycling

Verification of Functionality at Temperature Extreme : 85°C and

-40°C (compared to 25°C for UL 248)

Current Cycling : Simulates lifetime expectancy

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 Time-current Characteristics : 1,E+04

1 Heure

IEC gates :
1,E+03

Non melting current @1h :
INF = 1,13xIn
25A gPV

Melting current @1h :
IF = 1,45xIn 1,E+02

1 minute --

UL gates :

Temps (s)

Non melting current @1h : 1,E+01

INF = In

Melting current @1h :
IF = 1,35xIn
1,E+00

Mersen gates : (IEC and UL)

Non melting current @1h :
INF = 1,13xIn 1,E-01

Melting current @1h :

IF = 1,35xIn
1,E-02
10 100 1000
ISC In
Courant (A)

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 7. Example of time-currents curves
1,E+04

1 Heure gPV
IN > 1,4xISC

1,E+03
UN > UOCmax
gG

1,E+02
1 minute --

aM
Temps (s)

1,E+01

1,E+00

aR
1,E-01

1,E-02
10 100 1000
ISC IN
Courant (A)

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 example with panel data in chapter 2 :

Iscstc = 5,4A,

Fuses rating 1,4*Isc (7,6A) < Ir < 2*Isc (10,8A)

Fuse ratings could be 8A or 10A depend of the area

Melting gate à 1h is If = 1,45*Ir = 11.6A

For 2 strings, the Isc will be 5,4A : not enough to melt the fuse.
For 3 strings, the Isc will be 10.8A : not enough to melt the fuse.
For 4 strings, the Isc will be 16.2A : enough to melt the fuse.
Exemple N=2 Exemple N=3 Exemple N=4

ISC ISC 2ISC ISC 3ISC ISC ISC ISC

F F F F F F F F F

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 8. MERSEN FUSES

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 Dedicated solar brand delivers reliable, easy specification and
selection

Tested for night to day transition

Tested to electrical operate at extreme temperatures

Current cycled for increased liability and longevity

Brand Promise

Expertise in solar power applications

Premium offering for the PV industry

Delivering reliability and safety

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 Catalog Number Selection

Example: HP10M15

HP 10 M 15
Helio Protection Voltage Fuse Class Ampere Rating
Series
6 = 600VDC M = Midget
10 = 1000VDC J = Class J

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 3 New gPV Product Series with UL standard

Series HP6M HP10M HP6J

String or Module String or Module Array or Inverter
Application Protection Protection Input Protection
Voltage 600VDC 1000VDC 600VDC

Ampere 1-30A 1-30A 70-400A

Midget Midget
Size Class J
(10x38mm) (10x38mm)

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 4 gPV Product Series with IEC standard

Series HP6M HP10M DC10HEL DC120-123

String or
String or Module String or Module Array or Inverter
Application Protection Protection
Module
Input Protection
Protection
Voltage 600VDC 1000VDC 1200VDC 1200VDC

Ampere 1-30A 1-30A 8-20 50-400A

Midget Midget Midget

Size Main fuse
(10x38mm) (10x38mm) (10x85mm)

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 9. Application Overview

String Combiner Box

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 Array Combiner Box
Inverter Input

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 10. Applicable Customers

System Integrators and Contractors

Delivers: No-hassles, certainty

Solar Inverter OEMs

Delivers: Premium protection, cost savings, reliability

Combiner Box Manufacturers

Delivers: Premium protection, cost savings, reliability

Utility Power Generation and Distribution

Delivers: revenue generation – no downtime, safety

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 11. Product Resources
Collateral

Data Sheets
HP6M, HP10M, HP6J,
DC10, DC120-123

HelioProtection Program

Performance Curves
Time-Current Curves
Temperature De-rating
Watts Loss
Outline Drawings

PIQ Online Interative Quiz

(on US website)

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