Fuse rating calculation is an important factor of the electrical system

designing and installation. Also, if you are looking finding the the exact
status of your electrical installation, then you can get the Electrical
Installation Condition Report quote from the Energy North Ltd.

Some Fuse terminology to be remembered:

 Fuse sizing: Nearest size available with respect to rating

 Fuse rating: Exact duty of the fuse.

Motor Fuse sizing calculation:

For continuous running, The Motor fuse rating is equal to 1250 times
of motor real power P(kW) in kilowatts divided by the product of the
applied voltage V(V) in Volts and Power factor. Hence motor fuse rating
formula,

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Phase, 3 Phase

For single-phase:

Motor fuse rating = PkW x 1.25 / (pf x V(V))

In other words, the fuse rating is equal to 1.25 times the full load
current.

For Three-phase:

Motor fuse rating = PkW x 1250 / (1.732 x power factor x V(V-L))

 V(V-L) = Line to Line Voltage in volts.

For continuous operation, the fuse rating is less than the 125% is not
recommended since all the motor is designed to run 120% of the full
load rating. The under-capacity may lead to repeated tripping or
interruption of the operation.

Sometime, for high starting current application, we shall increase the

fuse rating to 1.5 times of the full load current.

However, any fuse sizing should compile type 2 co-coordination, (The

equipment should not register any physical damage in either
equipment side or stator equipment side. The equipment shall start
immediately after tripping)

But for electronics loads such as circuits, electronics transformer,

small motors, the fuse sizing will be the 1.1 times of the full load
current or 1.1 times of the total power in watts P (W) is divided by the
applied voltage V(V). Fuse rating formula for electronics circuit,

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Fuse rating for electronics circuit = 1.10 x PW / x V(V)

Fuse standard Sizing:

We cannot size exact resultant rating of the fuse from the above
formula. Instead, we can choose nearest available standard fuse size.
They are 1, 2, 3, 4, 6, 10, 16, 32, 40, 63, 125, 150, 160, 200, 250,
315, 355, 450, 500, 560, 630, 710, 800, 1000, 1250, 1600, 2000,
2500, 3200, 4000, 5000, and 6000 amperes.

Also, note that the fuse size can be designed at any Amps rating
which is depending on the manufacturer. i.e if you need 900A rated
fuse means, they can design.

Fuse rating Calculation:

Let we calculate the fuse sizing for 5.5kW 415V three-phase induction
motor is planned to run at 0.86 power factor.

Fuse rating = 1250 x 5.5 / (1.732 x 415 x 0.86) = 11.1 A

Hence, we can choose 16A Fuse for 5.5kW motor.

Motor Fuse Sizing Chart:

Here the standard IEC recommended fuse chart has been included.
But you can change the rated as per your load demand.

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Motor Fuse Sizing

Rating Motor Standard Sizing

kW A A

0.25 0.8 4

0.37 1.1 4
0.55 1.5 6

0.75 2 6

1.1 30 10

1.5 3.6 16

2.2 5 16

3 6.5 20

4 8.4 20

5.5 11 25

7.5 15 40

11 20 50

15 27 63

18.5 33 80

22 38 80

30 54 100

37 66 125

45 79 160

55 98 160

75 135 250

90 155 250

110 185 315

132 220 355

150 250 355

185 310 450

200 335 500

225 375 560

250 415 560

280 460 630

335 562 710

355 596 800

Fuse rating For Transformer:

For the transformer, the fuse rating is equal to the two times of the full
load current.

Fuse rating in Amps = 2 x Full load current

or in other words.,

The transformer fuse rating is equal to 2000 times of total apparent

power S(kVA) in kilovolts amp divided by the voltage V (V) in Volts. Hence
transformer fuse rating calculation formula will be,

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For single-phase:
 Transformer fuse rating = 2000 x S(kVA) / V(V)

For Three-phase transformer,

Transformer fuse rating = 2000 x S(kVA) / (1.732 x V(V-L))

Example:

Calculate the fuse sizing of the 250kVA, 415 V three-phase

transformer.

Fuse rating = 2000 x 250 / 1.732 x 415 = 696 Amps

Hence the nearest available size of the fuse is 710Amps.

Therefore, 250kVA transformer can be charged with the 710A fuse.

Fuse sizing for Lighting Circuits:

For the lighting circuit, the fuse current rating should be minimum 2
times the full load current of the total number of lighting.

For individual circuit, the fuse rating should be 1.5 times of the full
load current.

For example, let we calculate fuse rating for a 230 V, 0.8 pf light panel
and individual circuits and which contains 10 number of 400A mercury
vapour lighting.

Fuse rating for Panel:

Total connected load = 10 x 400 W = 4000 W

Hence the full load current = 4000 / (230*0.8) = 22A

Fuse rating = 2 x FLA = 2 x 22A = 44A

Hence the fuse standard rating for the panel should be 40A.

Learn More:   Resistance split-phase motor induction motor

Fuse rating for Individual Lighting Circuits:

Full load current for 400W lamp = 400 / (230 x 0.8) = 2.1

Fuse rating = 2 x 2.1 = 4.2A

Hence the fuse standard rating for the individual lamp should be 4A.

Fuse rating for Capacitor Circuits

For the capacitor circuit, the fuse rating is equal to 1.5 times of the full
load reactive current by considering staring inrush current, circuit
harmonics and capacitor tolerances. The formula will be

Capacitor Fuse rating = 1.5 x Capacitor Full load current

Or

Capacitor Fuse rating = 1.5 x Q(VAR) / (1.732 x V(V))

What is Fuse Video Explanation:

Previous articleWhat is Voltage Regulation?
Next articleWhat is Squirrel Cage Rotor?
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