Horn Gap Fuse

High-voltage electrical equipment is situated behind a chain-link fence topped with barbed wire. The area is a substation with large insulators and transformers, surrounded by gravel. Power lines and utility poles are visible in the background against a clear blue sky.

Horn Gap Fuse is a type of over current protection device used in medium-voltage overhead power distribution systems. It consists of a fuse wire suspended between two diverging metal "horns" mounted on insulators. When a fault or overload occurs, the fuse wire melts, and the resulting arc is stretched and extinguished as it rises along the horns.

We are Horn Gap Fuse manufacturers of different design for electrical overhead lines & substation. Our HG Fuse set / unit is suitable for worldwide uses with vertical & horizontal mounting features.

Types : Solid Core | Pin type | Post type
Voltage : 11 KV | 22 KV | 33 KV
Current Rating : 100 Amps | 200 Amps

Horn Gap Fuse working principle :

A horn gap fuse protects medium-voltage power lines by interrupting the circuit during over current or short-circuit conditions. It works using a fuse link and horn-shaped electrodes that help extinguish the arc safely. Step-by-Step : How a Horn Gap Fuse Works :-

1. Normal operation :-

A fuse wire (fuse link) connects two metallic horns mounted on insulators.
Electric current flows through the fuse link during normal operation.
The horns are stationary, diverging upward like a V-shape.

2. Fault or overload occurs :-

When current exceeds the fuse’s rated value (due to a short circuit or overload), the fuse wire melts.
As the wire breaks, an electric arc forms between the ends of the broken wire.

3. Arc formation and movement :-

The arc is conductive and hot, so it starts to rise due to:
- Thermal convection (hot air rises)
- Electromagnetic repulsion (due to the fault current)
As the arc rises, it travels up the diverging horns.

4. Arc extinguishes :-

As the arc moves up, the distance between the horns increases.
The longer the arc, the higher the resistance and the harder it is to maintain.
Eventually, the arc reaches a point where it cannot sustain itself and extinguishes.

5. Visual indication :-

After arc extinction, there’s a visible gap between the horn tips, showing the fuse has blown.
Line workers can easily see the open circuit from the ground.