Understanding Fuses and Fuse Boxes

Introduction

Fuses and fuse boxes are critical electrical safety components found in most homes and buildings. They play a vital role in preventing fires, equipment damage, and injuries by shutting off electricity when there is an overload or short circuit. Having a solid working knowledge of what fuses and fuse boxes do, how they operate, and when they need replacement or upgrades is essential for every homeowner and facility manager.

In this comprehensive guide, we will provide an in-depth look at the following topics related to understanding fuses and fuse boxes:

What is a Fuse?

Fuse definition and purpose
How fuses work
Types of fuses
Fuse ratings

What is a Fuse Box?

Fuse box definition
Locations and types of fuse boxes
Inside a fuse box

Identifying Fuses and Fuse Boxes

Markings and labels
Determining age and capacity

Inspecting and Replacing Fuses

Signs of a blown fuse
Replacing blown fuses
Upgrading fuse boxes and capacity

Fuse Box Safety Tips

Precautions and warnings
Load balancing
When to call an electrician

Equipped with this comprehensive overview of fuses and fuse boxes, you will have the knowledge to safely maintain, repair, and upgrade the critical electrical protection systems in your home or facility.

What is a Fuse?

A fuse is a safety device that protects electrical circuits from excessive current. Fuses help prevent fires, equipment damage, and injuries.

Fuse Definition and Purpose

Specifically, a fuse is a short piece of metal that melts and breaks when too much current flows through it, shutting off the power. It sacrifices itself to protect the wiring and devices downline from damage.

Fuses are placed in-line at strategic points along a circuit. They act as the weak point in the system that “blows” before wires overheat or expensive appliances and electronics are harmed.

How Fuses Work

Fuses work by heating up as electricity passes through the fuse material and causes resistance. Under normal current flows, they maintain a solid connection.

But when there is a surge, short circuit, or overloaded circuit, excessive current heats the small fuse wire past its melting point, causing it to burn through and break the connection. This stops the flow of dangerous amounts of current.

In essence, fuses trade off their inexpensive fuse wire to save the building, wiring, and costly equipment. Fuse boxes provide easy access to replace blown fuses with new ones and restore power.

Types of Fuses

There are two main categories of fuses: fast-acting and time-delay.

Fast-Acting or Quick-Blow Fuses: These fuses are designed to blow as quickly as possible when excess current flows. They use low-melting point fuse wire that reacts very quickly to cut off the power during short circuits and major overloads to prevent fire. However, they can sometimes blow prematurely from harmless temporary spikes in current.

Time-Delay or Slow-Blow Fuses: These fuses are made to withstand harmless short spikes in current from things like motors starting up. They use a higher melting point wire that delays the reaction time to 10-15 seconds or more in some cases. This prevents nuisance tripping, but the tradeoff is they allow some over-current for a time. A key role is protecting motors from damage if stalled.

In addition to fast-acting and time-delay types, there are:

One-time fuses that cannot be reused and must be fully replaced each time
Resettable fuses that can be reused by pushing a button or toggle switch to close the fuse contacts after it blows

Within these types are cartridge fuses, plug fuses, blade fuses, and more for different applications, voltages, and fuse box designs.

Fuse Ratings

Fuses are designed with specific current ratings and voltage limits that determine when they will blow. Standard ratings are 15 amps, 20 amps, 30 amps, up to 100 amps or more. This matches their role in protecting wires rated for those amp loads.

Voltage ratings ensure the fuse wire insulation does not arc over during operation. Common voltage ratings are 125V and 250V. Specialty fuses are made for 501V.

Fuse ratings are printed on the outside of the fuse to make it easy to match capacity and use. It is important to always replace blown fuses with ones of the identical capacity rating.

What is a Fuse Box?

A fuse box is an electrical panel that houses fuses and connects power coming into a building to various circuits going to appliances, lights, and outlets. Fuse boxes provide centralized access to fuses that protect all the separate branch circuits.

Fuse Box Definition

Specifically, a fuse box (also called fuse panel) is a metal box that mounts on a wall or along basement joists and contains an array of individual fuses controlling different circuits. Fuses plug into sockets to easily insert or remove them for replacement. The incoming power usually connects first to a main circuit breaker before branching out through the various fuses to distribute power throughout the electrical system.

Locations and Types of Fuse Boxes

Fuse panels are found in older homes built before the mid-1960s. Newer homes primarily use circuit breaker panels instead. But fuse boxes are still prominent in some locations:

Houses built 1950s or earlier
Electrical subpanels in outbuildings
Commercial and industrial applications

Some common types of fuse boxes include:

Main Fuse Box – Usually found in basements or utility areas, it receives the main power line feeding the home and routes electricity to subsidiary fuse boxes. May contain up to 60 fuses controlling individual rooms or areas of the home.
Supplementary Fuse Box – Added fuse boxes that supply power to detached garages, workshops, additions, and outdoor areas with multiple circuits. Have 10 to 20 fuse slots.
Knife Blade Fuses – An older 1930-1960s style fuse box using rectangular blades that fit into sockets. Blade fuses slide in and out.
Edison Base or Plug Fuses – Round screw-in fuses with threads that secure them into sockets. Multiple capacity ratings available.
Cartridge Fuses – Cylindrical glass or plastic body fuses for light commercial and industrial applications.

Inside a Fuse Box

Inside a typical main fuse box, you will see:

Fuse sockets – the receptacles that fuses plug into. Allows easy fuse access.
Bus bars – thick bars of copper that act like electrical highways, channeling main power into individual fuses.
Neutral bars – Provides the return path for electricity after passing through fuses to power circuits.
Grounding – Fuse box frame is grounded for safety. Some have a separate ground bar.
Main disconnect – Shutoff switch that cuts all power into the fuse box during repairs. Newer breaker panels combine main breaker and disconnect switch.
Knockouts – Openings allowing wires to enter and exit the box. May have protective bushing.

Proper identification of fuse capacity, labels, and order are very important inside the fuse box for safety and effective repairs.

Identifying Fuses and Fuse Boxes

When dealing with unknown fuse boxes in older homes, you first need to identify and understand what you are working with. Key steps include:

Markings and Labels

Examine fuses for ratings of amps and voltage to determine their capacity. This is printed on fuses.
Look for labels identifying which fuse powers each room. Often found on inside cover.
Trace wires back from individual fuses to determine which circuit they control.
Label any unknown fuses.

Determining Age and Capacity

Note the fuse styles – Edison base, cartridge, etc. Helps identify age.
Count number of fuse slots – more slots indicate larger capacity.
Note materials – porcelain knobs signal very old wiring.
Check manufacturer stampings on box for date.
Assess condition – corrosion, number of replaced fuses indicate age.
Estimate wire gauge coming into box – this reveals capacity.

With careful examination, you can determine the age, capacity, condition and idiosyncrasies of the fuse box to ensure proper maintenance and fuse replacement.

Inspecting and Replacing Fuses

When a fuse blows, it is important to not only replace it correctly but to also inspect for issues that caused the overload.

Signs of a Blown Fuse

Common signs your fuse has blown include:

Lack of power to outlets or lights in one area of home.
A popped or damaged fuse – melted wire indicates it blew.
Flipped fuse switch in the off position.
No continuity through fuse contacts when testing with multimeter.
Scorch marks or discolored paint around fuse. Points to short circuit issue.

If a fuse blows repeatedly, it likely indicates a serious underlying electrical problem, such as a short, old wiring, or too many appliances on the circuit. Never ignore a repeating fuse blow or replace a fuse over and over without troubleshooting the cause.

Replacing Blown Fuses

When replacing a blown fuse:

1. Disconnect the power source. Turn off the main fuse switch or breaker feeding the fuse box so it is de-energized.

2. Remove fuse. Wearing electrically insulated gloves, pull blown fuse out of its socket by the rim. Inspect it.

3. Check wires. Examine the fuse socket and end of wires for any discoloration or damage. Faulty wiring causes most repeated fuse blows.

4. Match new fuse capacity. Insert replacement fuse of the same voltage and amp rating that was blown. Using a higher capacity fuse can overload the wiring.

5. Check for fit. Replacement fuse should fit snugly in socket. If loose, try tightening socket screw or replace socket.

6. Restore power. Carefully return main power to fuse box. Blown fuses are often indicative of issues needing an electrician’s attention.

Upgrading Fuse Boxes and Capacity

Many older 60+ year old home fuse boxes lack capacity to handle increased electrical usage from modern appliances and devices. Warning signs include:

Frequent fuse failures and electrical overload trips.
Lack of open fuse slots for new circuits.
Old 2-wire system without separate ground wires.
Undersized wiring to the fuse box.
Sustained dimming or flickering lights indicating maxed out supply.
Higher electric bills from energy loss in old panels.

When fuse boxes show these types of deficiencies, its time to consider a complete replacement with a modern electrical panel and upgraded service capacity.

Typically upgraded home electrical service should provide 100 to 200 amps to meet most needs. Consulting an experienced electrician is highly recommended when replacing or upgrading aging fuse boxes.

Fuse Box Safety Tips

Working with electricity always demands proper safety including when maintaining or replacing fuses.

Precautions and Warnings

Use extreme caution when working inside a live fuse box – the exposure is hazardous.
Always turn OFF all power at the main breaker or switch before servicing fuses. Assume the box is live until you verify it is de-energized.
Respect electricity dangers – do not rush or skip steps when replacing fuses.
Wear insulating gloves and use insulated tools when replacing fuses. Remove rings and jewelry.
Never oversize a replacement fuse. Match amp ratings exactly or go slightly lower.
Do not tinfoil or “penny” a fuse to rig it. This causes extreme fire risk. Replace properly.
Stand on a dry surface and avoid any wet conditions when replacing fuses.

Load Balancing

Distribute electricity usage across circuits evenly in the fuse box. This can prevent overloaded circuits:

Don’t have all kitchen appliances on one circuit.
Alternate rooms on separate fuse circuits.
Adjust circuits to match fuse capacity.
Add new circuits and larger capacity fuses if needed.

When to Call an Electrician

Situations to have an electrician evaluate your fuse box include:

Old fuse box with no spare fuse slots.
Noticeable heat, soot, or scorch marks around fuses.
Recurring blown fuses with no explanation.
No labeling of fuse amp ratings or what they power.
Frequent tripped circuits under normal use.
Unsafe situations you are unsure how to address.
Major upgrades, repairs, or full replacement needed.

Electrical issues are the #1 cause of residential fires. Whenever in doubt about the safety of your fuse box, call a professional for assessment and repairs.

Frequently Asked Questions

What are some common signs my fuse is blown?

Some signs your fuse has blown include a lack of power downstream from the fuse, a visibly popped or melted fuse wire, the fuse switch flipped to “off”, scorch marks around the fuse, and no continuity through the fuse when testing with a multimeter.

Why do fuse boxes still exist if most homes have circuit breakers now?

Fuse boxes are outdated but still serve backup subpanels in many homes, outbuildings, RVs, and boats. Very old homes built before 1960 rely on original fuse boxes that can remain operational for decades. Some industrial applications still use fuses over breakers as well.

Is it safe to replace a blown fuse yourself?

Replacing standard screw-in or plug-in cartridge type fuses is generally safe with proper precautions like turning off all power, wearing insulated gloves, using insulated tools, and matching fuse ratings exactly. But call an electrician anytime you are unsure about working with your home’s older electrical system.

How do I add more circuits to my fuse box?

Adding new circuits requires replacing some existing fuses with higher capacity ones to free up space, adding a small subpanel off the main fuse box, or upgrading to a modern breaker panel. This is recommended work for a professional electrician due to safety risks.

What should I do about a fuse that keeps blowing repeatedly?

A fuse that blows continuously points to a serious problem like outdated wiring, a short circuit, or an overload on the circuit. The root cause needs to be addressed – just replacing the fuse over and over is extremely dangerous. Consulting an electrician to inspect and repair wiring is recommended.

Conclusion

Understanding exactly how fuses and fuse boxes operate allows you to use them safely and effectively. While no substitute for calling an electrician when in doubt, recognizing blown fuses, properly replacing them, and knowing when upgrades are needed are essential skills for homeowners.

Simple fuse box maintenance can prevent electrical hazards and costly outages. But always exercise caution and avoid tackling electrical issues beyond your training. In the hands of a professional, fuse boxes can continue protecting your home for decades to come.