TO BE READ BY ALL ELECTROSCHEMATICS ENTHUSIASTS!

Much needs to be said about this oft neglected subject. We would never even think of connecting the utility
mains to our house without proper circuit protectionalso, we must observe electrical codes. Low voltage
applications (under 24V), we say, are safeor are they? perhaps safe from electrical shock, but not short
circuits. Few know that the short circuit current of even a tiny alkaline 9V battery can exceed 5Ahow much
more a huge lead-acid battery such as is found in all automobiles and many solar systems. With lead-acid
storage batteries, the short circuit current could easily exceed 1000Aenough to destroy wiring if not properly
protected. Generally we think of protecting the connected device, but neglect the interconnecting wire.

Some websites are so paranoid about automotive modifications that they will not even allow discussions on
electronic circuits for automotive applications. However, note that your automobile represents a substantial
investment and deserves sensible circuit protection. While I have never seen an electrical fire in a vehicle, I
have seen a harness melt-down. Such is very expensive and/or laborious to replace. Circuit protection is
generally inexpensive and always should be observed.
Circuit protection devices include fuses, fusible links, circuit breakers and PTC current limiters. The following
is a concise list of the most inexpensive devices available from DigiKey.
Inline Fuse

Littlefuse inline fuse, 20A, DigiKey F062-ND $2.77 each (Includes 20A fuse)

Memory Protection Devices inline fuse, 10A, DigiKey BF301-ND $1.16 each

The inline fuse, though klunky in appearance is the least expensive means of protection. If connected close to
the power source, it provides protection for both the wiring and the connected devicesomething that circuit
breakers cannot do as well due to physical location. The Littlefuse inline fuse is available with or without pigtails. Generally inline fuses come with a loop that may be cut and spliced as required. Note the maximum load
current specification.
One caution is that if the fuse is removed, the contact could accidentally short to ground, or if reassembled
without the fuse, the contacts could short togetherkeep this in mind.
Fusible Link

These are made by Littlefuse. Your automotive shop is your best source of fusible links. While DigiKey no
longer offers them, they have a very nice FAQ page
http://media.digikey.com/pdf/Data%20Sheets/Littelfuse%20PDFs/Fusible_Link_FAQ.pdf
The fusible link is simply a wire gauge selection that is (4) wire sizes smallere.g. to protect an AWG #12
wire, an AWG #16 link would be used. The link wire has special, thick, high-temperature thermosetting
insulation (not thermoplastic that melts) that is capable of preventing harness meltdown. Unlike a fuse, they are
intended to protect wiring rather than equipment. Short circuit current is high and melting time is much longer
than an actual fuse. They are regularly used in automotive applications. Recently, I had to protect a cable
connecting two batteries in a recreational vehicleone battery located in the engine compartment, the other in
the rear. Because there were two power sources, the solution was a fusible link on each end of the cable.
Aircraft style circuit breaker

TE Connectivity /Tyco, W23 Series 50A, 50VDC Circuit Breaker, DigiKey PB411-ND
This is an aircraft style circuit breaker. They are available in current ratings from 1 to 50A. While these are
expensive at about $24 each, they provide the function of an On /Off switch as well. If you find some at a flea
market, grab them. Some have a toggle switch actuatorI like these better.
Rocker switch circuit breaker

Qualtek 736 series circuit breaker, 15A, 125VAC, DigiKey Q279-ND, $2.15 each
http://media.digikey.com/pdf/Data%20Sheets/Qualtek%20PDFs/736wb102.pdf
This is a good buy at $2.15 each. While this one is not specifically rated for 12VDC, it will provide good
protection because 12V is easy dutythe TE Connectivity competitor rates theirs at 50VDC. The probable
reason why it is not specified for DC is that some versions offer a neon indicator lamp that requires 115VAC. It
is also a possible marketing decision not to go after the low voltage market and thus save the additional cost of
agency approvals for the DC rating.
The following rocker breaker does have the DC rating.
TE Connectivity /Tyco W51 series, 15A, 50VDC, DigiKey PB1366-ND, $3.60 each
They are available in current ratings from 5 to 20A.
120/240VAC branch circuit protection circuit breaker
Why not? For experimentation this will work fine and they are easy to obtain. Current behaves the same in 12V
circuits as it does in 120/240V circuits.
Automotive circuit breaker

E-T-A 1610 series, 10A, 12VDC, DigiKey 302-1242-ND, $7 each

Automotive circuit breakers are of the automatic reset type that plug into the fuse box. While they offer circuit
protection, they are relatively expensive and generally are not practical for hobbyist applications.
Testing circuit breakers
Since there is nothing to replace, it is fun to throw a short across the breaker and see how quickly it trips.
PTC resettable fuse

Polyswitch RHE series, 15A, 16V, DigiKey RHEF1500-ND, $1.42 each

The PTC (positive temperature coefficient resistor) is a great circuit board level device. Because it never
actually blows, it never needs replacement. They are inexpensive and come in a great variety of package styles
and current ratings. The 15A version shown is one of the larger ones available.
Interrupting capacity, voltage rating and AC vs DC
The interrupting capacity rating is how much current the circuit breaker can safely interrupt in a short circuit
condition for a specified source voltage. For 120 /240VAC branch circuit protection, it is generally 5kA
(5000A). When any circuit is opened an electrical arc occurs. AC tends to extinguish the arc when the applied
voltage passes through zero volts, while DC tends to maintain the arc and is much more difficult to interrupt
when the voltage exceeds about 48VDC. For fusing DC circuits with significant voltage (50 to 700VDC), a
semiconductor fuse is generally specified. For 12VDC, interrupting capacity is generally not an issue because
low voltage systems have so much series resistance, that the current rarely exceeds about 2kA, and 12VDC is
insufficient voltage to maintain an arc across open contacts.
FYI, check out this link for a thermal breaker that is rated for low voltage marine installations:
http://www.flamecorp.com/Sensata/PDF/Sensata,%20F.pdf (Sensata was formally Airpax Corp.
Circuit breaker curves

The curve is the graphical presentation of trip time vs currentthe higher the current, the lower the tripping
time. Some are delayed acting so that moderate inrush over-current, such as occurs when some circuits are
closed, will not trip the breaker. Some have magnetic actuation that is much faster than thermalso fast that it
may have to be mechanically delayed slightly via a hydraulic damper to prevent nuisance tripping (magnetic
/hydraulic). The curve is generally not an issue unless the load is closely matched to the circuit breaker current
capacity.
Disconnecting an automotive battery
This is done simply by first unbolting the ground terminal. Why the ground terminal? Unlike the hot terminal,
the ground terminal has no voltage to ground, so there will be no SPARKS should the wrench accidentally
bridge the terminal to chassis. After the ground terminal is disconnected, the hot terminal may be safely
disconnected.
Lead-acid battery explosion
Keep flames away and avoid making any arcs near the battery. The hydrogen gas generated by a battery can
explode inside and/or outside the battery. This happened to mefortunately the acid did not spray in my face,
but it looked like my sweatshirt got hit with buckshot. Battery compartments always need ventilation.
Fuel pump disconnect switch
This is an inertial crash switch that turns off the fuel pump in the event of a crash thus preventing the electric
fuel pump from delivering a large amount a fuel in the event of a fuel line rupture. This is why cars often need
to be towed after only a bumper cruncher.
For the Future
Ground fault interrupter
Glossary of undocumented words and idioms for our ESL friends
Bumper cruncher minor automobile crash