Bussmann BP/FLB-60-RP 60 Amp Bolt-on Fusible Link Instruction Manual

1. Introduction

The Bussmann FL Series Fusible Link, model BP/FLB-60-RP, is designed for use in automotive 12 Volt applications. Its primary function is to provide additional wiring harness protection by acting as a sacrificial component that melts and breaks the circuit when an overcurrent condition occurs, preventing damage to more critical and expensive electrical components.

2. Safety Information

WARNING: Electrical work can be dangerous. Always disconnect the vehicle's battery before attempting any installation or replacement of electrical components. Failure to do so may result in electrical shock, fire, or damage to the vehicle's electrical system.

• Always ensure the vehicle's power supply is disconnected before handling the fusible link.
• Never replace a fusible link with one of a higher amperage rating than specified. This can lead to severe damage to the wiring or other components in the event of an electrical fault.
• If a fusible link blows, it indicates an electrical problem. Before replacing the link, identify and remedy the cause of the overcurrent condition. Simply replacing a blown link without addressing the underlying issue will likely result in another blown link.
• Wear appropriate personal protective equipment, such as safety glasses and insulated gloves, when working with electrical systems.
• This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm (Proposition 65 warning). Handle with care and wash hands after use.

3. Product Overview

The Bussmann BP/FLB-60-RP is a 60 Amp bolt-on fusible link designed for robust circuit protection. It features a durable plastic housing and copper terminals for secure connections.

Figure 3.1: Front view of the Bussmann BP/FLB-60-RP 60 Amp Bolt-on Fusible Link.

Key Features:

• Amperage Rating: 60 Amperes
• Terminal Type: 13/16 inch bolt terminal, designed to bolt directly to a fuse block or other connection point.
• Voltage Rating: 12 Volt DC applications.
• Color: Yellow, for easy identification of its amperage rating (standard color coding for 60A).
• Construction: Plastic body with copper terminals.

Figure 3.2: Side view of the Bussmann BP/FLB-60-RP in its retail packaging, showing the bolt-on terminal design.

4. Specifications

5. Installation

This section provides general guidelines for installing the Bussmann BP/FLB-60-RP fusible link. Always refer to your vehicle's specific service manual for detailed wiring diagrams and procedures.

1. Disconnect Power: Before beginning any work, disconnect the negative terminal of the vehicle's battery to prevent accidental short circuits or electrical shock.
2. Locate Fuse Block/Connection Point: Identify the specific fuse block or wiring harness connection point where the fusible link needs to be installed or replaced.
3. Remove Old Fusible Link (if replacing): If replacing an existing fusible link, carefully unbolt or disconnect it from the terminals. Note the orientation and connection points.
4. Prepare Connection: Ensure the connection points are clean and free of corrosion.
5. Install New Fusible Link: Position the new Bussmann BP/FLB-60-RP fusible link. The 13/16 inch bolt terminals are designed to be bolted directly to the appropriate connection points. Ensure a secure and tight connection to maintain proper electrical contact.
6. Verify Amperage: Double-check that the installed fusible link is the correct 60 Amp rating for the circuit it is protecting.
7. Reconnect Power: Once the fusible link is securely installed and all connections are verified, reconnect the negative terminal of the vehicle's battery.
8. Test Circuit: Test the electrical circuit to ensure proper operation.

Figure 5.1: Packaging of the Bussmann BP/FLB-60-RP, indicating its bolt-on design and general application.

6. Operation

The Bussmann BP/FLB-60-RP fusible link operates passively as a safety device. Under normal operating conditions, it allows electrical current to flow through the circuit without interruption. If an electrical fault occurs, such as a short circuit or an excessive current draw that exceeds 60 amperes, the internal element of the fusible link will melt and open the circuit. This action protects the vehicle's wiring and other electrical components from overheating and potential damage.

The yellow color of the fusible link is a standard indicator for its 60 Amp rating, aiding in quick identification and ensuring the correct replacement is used if necessary.

7. Maintenance

Fusible links are generally maintenance-free components. They are designed to function until an overcurrent event causes them to blow. No routine maintenance is required for the fusible link itself.

Replacement: If the fusible link blows, it must be replaced. Always replace it with a new Bussmann BP/FLB-60-RP 60 Amp fusible link or an equivalent with the exact same amperage rating and specifications. Never attempt to repair a blown fusible link.

8. Troubleshooting

If a circuit protected by the BP/FLB-60-RP fusible link loses power, the fusible link may have blown. Follow these troubleshooting steps:

1. Verify Power Loss: Confirm that the specific circuit is indeed without power.
2. Visual Inspection: Disconnect the battery and visually inspect the fusible link. A blown fusible link will often show signs of melting or discoloration in its plastic housing, or the internal wire will be visibly broken.
3. Identify Cause: Crucially, before replacing the fusible link, determine the cause of the overcurrent. Common causes include:
   • Short circuit in the wiring or connected component.
   • Overloaded circuit due to too many accessories or a faulty component drawing excessive current.
   • Damaged wiring insulation.
   Failure to address the root cause will result in the new fusible link blowing immediately or shortly after replacement.
4. Replace Fusible Link: Once the cause is identified and remedied, replace the blown fusible link with a new Bussmann BP/FLB-60-RP (60 Amp) following the installation instructions in Section 5.
5. Test: Reconnect the battery and test the circuit.

9. Support and Contact Information

For further assistance, technical support, or information regarding Bussmann products, please visit the official Bussmann website or contact customer service.

• Manufacturer: Eaton's Bussmann Division
• Website: Eaton.com/BussmannConsumer
• Address: Cooper Bussmann, LLC, 114 Old State Road, Ellisville, MO 63021
• Phone: 1-877-359-2075