Electronic – what size of copper wire can act as a 150A fuse

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If I would like to use a piece of copper wire as a 150A fuse, what size of wire should I use?

It doesn't have to be 150A very accurately, the parameters I need the wire to meet are:

  • it needs to conduct continuously 70A 10V-30V DC without getting red or overheating
  • it needs to conduct 120A sometimes for 15 seconds without melting
  • it needs to surely be melted before the current reaches 200A

Easily available wires over here are: 0.5 mm^2, 0.75 mm^2, 1.0 mm^2, 1.5 mm^2, 2.5 mm^2, 4 mm^2, 6 mm^2, 10 mm^2. Will any of these do the job? I can combine a few if the required value is not in the above series.


Edit: now I read more into the specifications of the device, and it is in fact rated to be fine with 600A for 5 seconds. Besides that I will be only ever using it continuously with 50A. Is that gap (50A – 600A) large enough to make a fuse out of copper?

This table of AWG wire sizes suggests that a 2.5mm^2 copper wire will melt with about 750A in 1s, and with a little under 200A in 10s, so it looks like it will melt in time for the device not to be damaged. The device itself is wired with 10mm^2 insulated wire, and I mostly worry about that wire not to be damaged.

Now I only need to find out to what temperature will a short piece of uninsulated 2.5mm^2 copper wire heat-up with 50A continuous current flow, and will it not melt the thing it is secured in at that temperature.

By "continuous" use I mean max 1 hour at a time, with full attendance of me, so it will not run unattended like this.


More info: The machine came originally with two 50A fuses wired in parallel. In fact I want to use a wire, because the fuses blow so often it starts to get expensive, on average I need 1 fuse per 1 hour of charging, so the fuses cost more then the electricity to power this. I don't know why they blow, because I have an ammeter wired in series with the fuse, and I never seen anything over 60A on the ammeter! The fuses don't blow randomly, I just can see the fuse slowly get red, it stays red for some time, and at one point it just melts. I've been watching this process and I didn't see over 60A while the fuse was melting, I was watching the ammeter all the time in the slow process of the fuse being melted. So if I need 1 fuse per hour, so be it, but I need some cheaper option then 50 cents a fuse if I am to use them at that rate.

Best Answer

Finding a fuse with those characteristics is going to be difficult. I'd use a current shunt with a suitable MCU and circuit breaker and monitor the current taken by the device, shutting off the current if it rises above 120A for 15 seconds.

Two fuses in parallel can cause problems unless they are well-matched and the holders are properly designed. Any difference between them can cause one fuse to take more current than the other one, and fail.

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