Scope

This instruction provides information on periodic inspection of indicating-type fuses and fuseholders manufactured to MIL-PRF-I9207.

Applicability
This instruction is applicable to all instrumentation and control technical manuals.

Special Tools and Equipment

Not applicable.

Instruction
General
Some indicator types of panel-mounted fuse receptacles contain riveted connections which carry current. The latest requirements of MIL-PRF-19207 require these connections (Figure 1) to be soldered to achieve a low-resistance connection. A loose-riveted connection in a fuseholder can result in intermittent equipment operation or damage to the fuseholder due to heating caused by poor electrical contact (higher than normal contact resistance). When a fuse is removed, a visual and mechanical inspection of these connections should be made to ensure that mechanically sound, low-resistance electrical connections exist, and any fuseholders which are found to contain defective riveted connections should be replaced.

Figure 1 - Fuseholder Assembly

Also, some fuseholders have a spring loaded terminal stud which connects the fuse carriage to the supply line. This connection is made by spring pressure when the fuse carriage is inserted in the fuseholder. If this feature is degraded, a poor electrical contact between the fuse carriage and the line side terminal stud can occur. The stud may become jammed due to improper wiring harness installation, improper terminal lug orientation, or jamming of the stud in the fuse housing. Improper line side terminal stud spring action may lead to intermittent equipment operation or fuseholder damage. Some fuseholders (Figure 2) have a metal tab that protrudes internally from the side of the fuseholder which supplies power to the blown-fuse indicating circuit within the fuse cap. This metal tab may break off due to the twisting action of removing or installing the fuse cap, or by catching the end of the fuse during fuse insertion. This may lead to the inability to indicate a blown fuse.

Inspection Procedure
Prior to performing the inspections, power to the fuseholder which is to be inspected must be removed.

Inspection of Riveted Connections

Check the riveted connection inside the fuseholder by removing the fuse carriage and observing the riveted strap inside the fuseholder. If the area around the strap has been damaged (shows signs of arcing or overheating), replace the fuseholder. Some fuseholders may have riveted connections that cannot be visually examined. If the riveted connection in a fuseholder cannot be visually examined without optical aid, the fuseholder need not be replaced if it is otherwise satisfactory, that is, shows no signs of arcing or overheating. Check the riveted connections on the fuse carriage by removing the fuse and checking the riveted connections for looseness or damage (signs of arcing or overheating). If either condition exists, replace the fuse carriage. Also check that the clips make good contact with the fuses. The fuse carriage rivets are the most susceptible to damage, and care should be taken when fuses are removed from and installed in the clips. When the fuse carriage is inserted into the fuseholder, check for spring tension on the carriage. If no spring tension is felt, replace or repair the fuseholder. Visually inspect indicating type fuseholders for broken or cracked indicating bulbs or resistors. Chips or hairline cracks in fuse indicators (twist lock or carriage) are acceptable. Chips or cracks which compromise enclosure should be replaced. If available, use replacement fuseholders and fusecarriers that have riveted electrical connections that have been soldered per MIL-PRF-19207C.

Inspection of Fuseholder Test Points

If the fuseholder contains a test point, visually check to determine if the electrical connection in the test point is recessed sufficiently that it cannot be inadvertently touched by personnel. If the electrical connection is not recessed sufficiently to prevent inadvertent touching, determine if the rivet or washer in the test hole can be pushed into the hole by pushing on the rivet or washer with a tool small enough to be inserted into the test hole. If the test point cannot be recessed, or if it will not remain recessed, replace the fuseholder.

Verification of Fuseholder Terminal Connection Tightness

The tightness of fuseholder terminal connections should be verified. This check is not required if electrical buswork must be disassembled or cabinet wiring or internal components must be disconnected or removed to gain access to the fuseholder terminal connections.

Inspection of Fuseholder Terminal Lug Insulation and Orientation

Some fuses may have load-side (fixed) terminals which extend beyond the line-side (spring-loaded) terminal housing. When the fuse carriage is removed, spring decompression allows the line-side terminal to move toward the housing, causing a short circuit if the terminal lugs are not properly oriented or insulated. Check for proper lug barrel insulation on both terminals and that the line-side terminal lugs are oriented away from the load-side terminal and lugs.

Inspection of Fuseholder Line-Side Spring Loaded Contact

The line-side contact/stud is spring loaded to ensure good contact with the mating fuse carriage contact. The spring loaded feature should be checked by depressing the fuse carriage into the fuse holder and releasing. The fuse carriage should travel inward freely and return by spring action. If no spring action is felt, remove the fuseholder and inspect to ensure that the line-side contact/stud is not jammed and inspect the cabinet to ensure proper wiring harness installation and proper terminal lug orientation.

Inspection of Fuseholder Blown-Fuse Indicating Circuit Power Supply Tab

If the fuseholder contains a metal tab that protrudes internally from the side of the fuseholder which supplies power to the blown-fuse indicating circuit within the fuse cap, visually check the metal tab. Check that the tab has not broken off, is not twisted, does not extend excessively into the fuseholder chamber, and is able to compress within the chamber. If the metal tab fails any of these inspection criteria, replace the fuseholder.

Fuseholder O-Ring Lubrication

Lubrication originally applied to O-ring seals on twist lock type fuseholders can be worn away over an extended period of time causing binding and difficulty in properly locking the fuse carriage in place. If binding occurs, apply a small amount of silicone compound per A-A-59691 (formerly MIL-S-8660) (dielectric and moisture sealant) to the O-ring seal to reduce friction.

Figure 2 - Fuseholder with Metal Tab