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School me: Fuses vs. Auto-resetting Breakers

colbystephens

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I'm looking at a couple different wiring harnesses for doing a Ford Windstar cooling fan swap. One comes with an auto-resetting breaker, and the other comes with an inline fuse. It got me to wondering:

When is it more appropriate to run a fuse, and when is it more appropriate to run an auto-resetting breaker?

My headlight relay modification runs a breaker. I think I chose that instead of a fuse because it would allow me to limp home in the dark if something happened (maybe).
 
Really no functional difference either way. Only advantage of a breaker is if the load powered by the breaker is unpredictable or changes a lot (like what happens when people connector different appliances to an outlet in the house).

In a vehicle, the expected max load is pretty predictable and so there's no reason to run a breaker which is much more expensive than a fuse. If you have a circuit that's blowing fuses a lot, there's another problem that needs to be fixed. I don't see how a breaker would help you limp home unless a circuit was slowing heating up before it popped the breaker rather than popping from a dead short (which is much more likely in a vehicle).
 
I would think a fuse would be more appropriate on sensitive equipment.

An auto resetting breaker could potentially keep hitting the equipment with voltage over and over until the fault is corrected.

I have had the same question myself and that's the only reason I can come up with.
 
I did a little reading on this topic and I feel like it really comes down to preference. Ultimately I went with fuses because of price and availability. It's also nice to be able to just pull a fuse to isolate a circuit for work.

I did have a mechanic friend of mine warn me about using cheap fuses. In a one month span he had 3 different vehicles come in with damage due to a fuse not functioning properly, as in not blowing and causing things to melt. I ordered a bunch of Bussmann fuses from Summit to be safe.

In theory you can limp home with fuses by putting in a larger fuse.
 
The autoresetting breakers are generally used on vital safety equipment that will not do damage if restarted.
For instance, I'm pretty sure that DOT still requires that all headlights use autos. I made the mistake of upping the wattage on my old truck one time, and it was too much for the worn beaker in the headlight switch.
About a mile down the road, they started blinking on and off.

I was able to limp into a late night parts house and buy a new switch. It held for a couple of weeks until I got a chance to add a dual relay with internal resetting breakers.
Fuses are usually required where its dangerous for a piece of equipment to restart without warning.
But, not always. I often work on big motors that have warning stickers saying that it has a self resetting overload and can restart without warning.

Often its just a matter of personal preference. However, the selfies can cause big problems.
A motor that is stalled, and trips the breaker can overheat and burn up or even cause a fire if it keeps getting voltage too often.
The self resetting overloads on a motor are usually mounted in contact with the motor case, and react to both overload and heat.
So, if the motor cannot start and begins to overheat from repeated trying, it will stop trying until it cools off.

Don't forget to consider the third alternative. Manual resetting breakers. They stay off like a fuse, but you don't have to carry replacements.
I put one on my turn signal when it started blowing fuses randomly. It might go months between problems, or happen a couple of times in one day.

The short cleared up as soon as it happened, so there was no way to find it. I mounted the breaker on the dash where I could hit the reset button.

Also remember in general, you can get fuses that blow faster than breakers. So critical current sensitive equipment is better protected.

Just to stir the mix, they also make solid state fuses. They "blow" when they see too much current, and stay blown as long as the overload exists.
When its cleared, they reset.
 
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