Description
ANL/C125SF35 50A-350A 125V Energy storage fuse
1.Dimensions- mm
2.Product Features
- Mild Hybrid Vehicles
- Vehicle Power Distribution (Electric Vehicles, Electric Motorcycles)
- Material Handling Systems
- All Supercapacitors and Battery Systems
- High Current Line Protection
- Compact Design for High Current Applications
- Rated Voltage: Below 125Vdc
- Plastic Housing (PBT, PPS，Ceramics), Screw-on Terminal Design
- Compliant with: UL248-13Standard
- Operating Temperature: -40 to 125℃degrees
3.Electrical Characteristics
| % of Rating | Opening Time Min / Max |
| 50A – 350A | |
| 100 | 4H / ∞ |
| 300 | ~/10S |
4.Product specifications
| Part Number | Rated current (A) | Voltage Rating
(v) |
Melting I²t(Pre-arcing)
A²s |
Arcing I²t A²s | Clearing I²t(Total)
A²s |
| ANL-C125050SF35 | 50A | 48V
63V 80V 125V
|
250 | 150 | 400 |
| ANL-C125060SF35 | 60A | 360 | 216 | 576 | |
| ANL-C125080SF35 | 80A | 640 | 384 | 1024 | |
| ANL-C125100SF35 | 100A | 1250 | 750 | 2000 | |
| ANL-C125150SF35 | 150A | 2230 | 1338 | 3568 | |
| ANL-C125200SF35 | 200A | 5400 | 3240 | 8640 | |
| ANL-C125250SF35 | 250A | 9600 | 5760 | 15360 | |
| ANL-C125300SF35 | 300A | 21800 | 13080 | 34880 | |
| ANL-C125350SF35 | 350A | 38500 | 23100 | 61600 |
Note: Different currents and standards can be customized according to customer requirements
Test Condition: 10× rated current, DC 125V, 25℃ ambient temperature, tolerance ±10%
1. Executive Summary
The ANL/C125SF35 series is a specialized high-current DC fuse developed exclusively for low-voltage energy storage systems (ESS), battery energy storage systems (BESS), electric vehicles, off-grid solar power and industrial DC distribution networks. Designed per ANL standard mounting form factor, this product covers current ratings from 50A to 350A with a nominal DC voltage of 125V.
Different from conventional automotive and general-purpose industrial fuses, the ANL-C125SF35 adopts optimized arc-extinguishing structure, high-purity conductive materials and temperature-resistant engineering plastics. It delivers outstanding performance on DC fault current interruption, thermal cycling resistance and long-term operational stability, which fully meets the stringent protection requirements of lithium battery energy storage circuits. This document elaborates on electrical parameters, structural design, performance characteristics, application scenarios, selection criteria, installation specifications and safety guidelines for engineering reference.
2. Product Overview & Design Principle
1 Design Background
DC circuits for energy storage present unique technical challenges compared with AC circuits: DC current has no natural current zero crossing, resulting in longer arc duration and higher arc energy during short-circuit faults. Meanwhile, frequent charge-discharge cycles of lithium batteries cause continuous thermal shock to protective components.
Conventional fuses are not structurally optimized for such operating conditions, which easily leads to arc reignition, premature aging or failure to break faults. The ANL-C125SF35 series is targeted at these pain points, with core design objectives as below:
- Realize rapid arc extinction under 125V DC high fault current;
- Resist thermal fatigue caused by long-term charge-discharge cycling;
- Maintain low contact resistance to reduce system power loss;
- Comply with universal ANL bolt-on installation standard for easy compatibility with existing fuse bases.
2 Structural Composition
The fuse consists of four core parts: fuse element, arc-extinguishing medium, insulating housing and conductive terminal.
- Fuse Element: Silver-plated copper alloy, precisely processed with multi-section constricted structure. Ensures accurate fusing characteristic and low temperature rise under rated current.
- Arc-extinguishing Medium: High-purity quartz sand with graded particle size, densely filled inside the housing. Quickly absorbs arc energy and cools conductive plasma to cut off fault arc.
- Insulating Housing: High-temperature resistant flame-retardant thermoplastic, excellent mechanical strength and insulation performance, anti-cracking under sudden temperature change.
- Conductive Terminal: Tin-plated brass terminal block, anti-oxidation and anti-corrosion, guarantees stable connection performance under high current.
3. Complete Technical Specifications
3.1 Basic Electrical Ratings
| Item | Parameter |
|---|---|
| Model Series | ANL/C125SF35 |
| Nominal Rated Voltage | 125V DC |
| Rated Current Range | 50A, 60A, 80A, 100A, 125A, 150A, 200A, 250A, 300A, 350A |
| Rated Breaking Capacity | 10 kA DC (at 125V DC) |
| Pre-arcing Time (Short Circuit) | ≤ 10 ms |
| Total Clearing Time | ≤ 20 ms |
| Typical I²t Value | Low energy let-through, compatible with semiconductor and lithium battery protection |
| Power Frequency Withstand Voltage | 500V AC / 1min, no breakdown |
3.2 Mechanical & Physical Parameters
- Mounting Type: ANL standard bolt-on installation
- Overall Dimension: 82 mm × 20 mm × 8.5 mm
- Recommended Bolt Torque: 8 ~ 10 N·m
- Weight: 45 ± 3 g (per piece)
3.3 Environmental Adaptability
- Operating Ambient Temperature: -40 ℃ ~ +85 ℃
- Storage Temperature: -50 ℃ ~ +90 ℃
- Maximum Operating Altitude: 5000 m
- Current Derating Rule: For altitude above 2000 m or ambient temperature above 60 ℃, derate rated current by 10% per 10 ℃ temperature rise.
- Vibration Resistance: Compliant with IEC 60068-2-6, suitable for mobile equipment such as electric vehicles and engineering vehicles.
3.4 Compliance & Certification
- Execution Standards: UL 248-13, IEC 60269-4
- Environmental Compliance: RoHS 2.0, REACH
- Flame Retardant Grade: UL94 V0
3.5 Contact Resistance & Temperature Rise
- Initial Contact Resistance: ≤ 15 μΩ
- Temperature Rise: Under 100% rated current, steady-state temperature rise ≤ 40 K (ambient 25 ℃)
4. Core Performance Advantages
4.1 Superior DC Arc Extinguishing Performance
Aimed at the characteristic of DC non-zero crossing arc, the graded quartz sand filling and optimized constricted element structure are adopted. When short circuit occurs, the element fuses instantly, and the quartz sand rapidly cools and splits the arc, effectively suppressing arc reignition. It can stably break 10kA high fault current under 125V DC, fully avoiding equipment burnout and fire risks caused by persistent arc.
4.2 Excellent Thermal Cycling Durability
The silver-plated copper fuse element has strong anti-oxidation and anti-fatigue capability. After thousands of charge-discharge cycle tests simulating ESS working conditions, no deformation, oxidation or performance attenuation occurs. It solves the problem of premature blowout of ordinary fuses in frequent cycle working scenarios.
4.3 Low Power Loss & High System Efficiency
High-conductivity materials and precision machining minimize internal resistance. Under long-term rated current operation, the heat generation is low, which not only reduces invalid power consumption of the system, but also lowers the ambient temperature inside the cabinet and extends the service life of surrounding electrical components.
4.4 Universal Compatibility & Easy Installation
Adopts industry-standard ANL external size and bolt-on terminal layout. It is interchangeable with traditional ANL fuses, compatible with mainstream ANL fuse holders in the market. No special tools or structural modification are required during assembly, which greatly improves on-site installation and maintenance efficiency.
4.5 High Safety & Reliability
Flame-retardant and impact-resistant housing can withstand instantaneous high pressure and heat generated during fusing. No shell rupture, molten metal splashing or flame overflow occurs under fault conditions, ensuring personnel and equipment safety.
5. Typical Application Fields
The ANL/C125SF35 series is specially designed for 125V DC high-current circuits, mainly applied in the following professional fields:
5.1 Battery Energy Storage System (BESS)
- Parallel protection of lithium battery strings in low-voltage BESS cabinet
- Overcurrent and short-circuit protection for battery combiner box
- Circuit protection for BMS, DC/DC converter and auxiliary power loop of energy storage cabinet
5.2 Electric Vehicles & Mobile Engineering Equipment
- Main circuit protection for low-voltage heavy-duty electric vehicles
- Power circuit protection for electric forklifts, AGVs, electric golf carts and recreational vehicles
- Auxiliary battery system protection for commercial electric vehicles
5.3 Solar & New Energy Storage System
- Overcurrent protection of off-grid solar battery banks (125V DC system)
- Output terminal protection of solar charge controller
- Circuit protection for hybrid solar-wind integrated energy storage system
5.4 Industrial DC Power & Telecommunication Backup Power
- 125V DC industrial power distribution cabinet
- DC UPS system for industrial workshop
- Telecommunication base station battery backup system
Note: This series is rated for DC application only. It is prohibited to use in AC circuits beyond the specified scope.
6. Engineering Selection Guidelines
Correct fuse selection is the premise to ensure protective performance and normal system operation. Follow the rules below for model selection:
6.1 Rated Current Selection
- For continuous steady load: Select fuse rated current = 1.25 ~ 1.5 times of the maximum continuous operating current of the circuit.
Example: Circuit continuous current 200A → select ANL-C125SF35-250A.
- For circuits with frequent startup and impact current: Select fuse rated current = 1.5 ~ 2 times of steady load current, to avoid nuisance tripping.
- After temperature and altitude derating, the actual allowable current of the fuse shall still be greater than the maximum operating current of the circuit.
6.2 Voltage Matching
The nominal voltage of the fuse (125V DC) must be greater than or equal to the maximum working voltage of the system. Do not use this fuse in systems with DC voltage higher than 125V.
6.3 Breaking Capacity Verification
Calculate the maximum prospective short-circuit current of the protected circuit. The value shall not exceed the fuse rated breaking capacity (10kA DC). If the short-circuit current exceeds the standard, upgrade the protection scheme.
6.4 Protection Coordination
Realize selective protection between upstream and downstream protective devices. Match the fusing characteristic of ANL/C125SF35 with circuit breakers and other fuses, to ensure only the faulty branch fuse operates during faults, and avoid overall system power failure.
7. Installation, Operation & Maintenance Specifications
7.1 Installation Requirements
- Match with standard ANL fuse holder; check the holder for deformation, oxidation or loose spring before installation.
- Use a torque wrench to fasten the terminal bolts, control torque within 8 ~ 10 N·m. Excess torque will damage the terminal, while insufficient torque will cause poor contact and overheating.
- Installation position: Keep horizontal layout as priority, ensure unobstructed ventilation around the fuse, and reserve no less than 10mm heat dissipation gap.
- Do not install in enclosed narrow space without heat dissipation measures.
7.2 Daily Operation Inspection
- Regularly check the fuse appearance: no shell discoloration, cracking or scorch mark.
- Check terminal connection status: no oxidation, rust or abnormal temperature rise.
- For systems running under high load for a long time, conduct infrared temperature measurement periodically to monitor temperature rise.
7.3 Replacement Rules After Fusing
- Cut off the system power completely before replacement, confirm no residual voltage in the circuit.
- Replace with the same model and same rated current fuse strictly; do not use fuses with higher current rating or non-matching products instead.
- After fuse blowout, first troubleshoot the fault cause (short circuit, overload, circuit abnormality), then replace the fuse and power on again.
7.4 Safety Prohibition
- It is forbidden to modify the fuse structure or repair the blown fuse for reuse.
- It is forbidden to use wire, metal sheet and other conductors to replace the fuse.
- It is forbidden to work with power on during installation and replacement.
8. Troubleshooting & Common Problems
8.1 Nuisance Tripping (Fuse Blows Without Fault)
- Cause: Fuse current rating selected too small; excessive impact current; loose terminal connection leading to local overheating.
- Solution: Recheck load current and re-select model; optimize circuit startup strategy; re-tighten terminals per standard torque.
8.2 Fuse Body Overheating During Operation
- Cause: Insufficient fastening torque; poor contact of fuse holder; ambient temperature too high or poor ventilation.
- Solution: Re-fasten bolts; replace aging fuse holder; improve cabinet heat dissipation or implement current derating.
8.3 Failure to Break Short-Circuit Fault
- Cause: System voltage exceeds 125V DC; prospective short-circuit current exceeds 10kA; wrong model selection.
- Solution: Re-verify system electrical parameters and replace with matched high-specification fuse.
9. Conclusion
The ANL-C125SF35 125V DC energy storage fuse is a professional protective component tailored for low-voltage high-current DC energy storage industry. With reliable DC fault breaking capability, outstanding thermal cycle resistance, low power loss and universal installation compatibility, it can effectively protect lithium batteries, converters and DC distribution circuits in ESS, electric vehicles and new energy systems.
Following the technical specifications, selection rules and installation standards in this manual can maximize the service life and protective performance of the product. For large-scale project matching and customized technical support, please contact our engineering team for further technical docking.
FAQ (Technical Q&A)
1: Can ANL-C125SF35 be used in AC circuits?
1): No. This product is designed for DC 125V system. Its arc-extinguishing structure and electrical characteristics are not applicable to AC circuits, which will lead to failure to break faults and safety hazards.
2: What is the service life of the fuse under normal working conditions?
2): Under rated current, normal temperature and standard working environment, the service life is consistent with the whole life cycle of the equipment. It will not age or fail due to long-term normal operation.
3: Is current derating required when used in high altitude areas?
3): Yes. When the altitude is higher than 2000m, current derating is required to ensure operation safety.
4: What is the difference between this fuse and ordinary ANL automotive fuses?
4): Ordinary ANL fuses are mainly for low-voltage AC/short-time DC of automobiles, with low DC voltage resistance and poor arc extinction performance. ANL-C125SF35 is optimized for 125V DC and frequent charge-discharge cycles, specially for energy storage systems.