U.S. patent application number 13/753793 was filed with the patent office on 2014-07-31 for annunciating or power vending circuit breaker for an electric load.
This patent application is currently assigned to EATON CORPORATION. The applicant listed for this patent is EATON CORPORATION. Invention is credited to DAVID AUSTIN ELDRIDGE, JASON-DAVID NITZBERG, BRANDON J. ROGERS, RONALD L. THOMPSON.
Application Number | 20140211345 13/753793 |
Document ID | / |
Family ID | 50071789 |
Filed Date | 2014-07-31 |
United States Patent
Application |
20140211345 |
Kind Code |
A1 |
THOMPSON; RONALD L. ; et
al. |
July 31, 2014 |
ANNUNCIATING OR POWER VENDING CIRCUIT BREAKER FOR AN ELECTRIC
LOAD
Abstract
A circuit breaker for an electric load includes first and second
terminals; a number of first separable contacts each electrically
connected between one of the first terminals and one of the second
terminals; a first mechanism to open, close or trip open the first
contacts; a number of second separable contacts each electrically
connected in series with a corresponding one of the first contacts;
a second mechanism to open or close the second contacts; a
processor to cause the second mechanism to open or close the second
contacts, annunciate through one of the second terminals a power
circuit electrical parameter for the electric load, receive from a
number of the second terminals a confirmation from or on behalf of
the electric load to cause the second mechanism to close the second
contacts, and determine a fault state operatively associated with
current flowing through the second contacts.
Inventors: |
THOMPSON; RONALD L.;
(KNOXVILLE, TN) ; NITZBERG; JASON-DAVID;
(CINCINNATI, OH) ; ELDRIDGE; DAVID AUSTIN;
(KNOXVILLE, TN) ; ROGERS; BRANDON J.; (KNOXVILLE,
TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
EATON CORPORATION |
CLEVELAND |
OH |
US |
|
|
Assignee: |
EATON CORPORATION
CLEVELAND
OH
|
Family ID: |
50071789 |
Appl. No.: |
13/753793 |
Filed: |
January 30, 2013 |
Current U.S.
Class: |
361/42 ;
335/11 |
Current CPC
Class: |
Y02T 90/14 20130101;
Y02T 90/16 20130101; H02H 3/33 20130101; H02H 3/006 20130101; Y04S
30/14 20130101; Y02T 90/167 20130101; H01H 9/548 20130101; Y02T
10/70 20130101; B60L 3/00 20130101; B60L 3/0069 20130101; B60L
53/18 20190201; H02J 3/008 20130101; Y04S 30/12 20130101; H02J
13/00 20130101; B60L 53/68 20190201; H01H 83/02 20130101; H02H
1/0061 20130101; Y02T 90/12 20130101; B60L 53/51 20190201; B60L
53/305 20190201; Y02T 10/7072 20130101; B60L 3/04 20130101; B60L
53/665 20190201 |
Class at
Publication: |
361/42 ;
335/11 |
International
Class: |
H01H 9/54 20060101
H01H009/54; H01H 83/02 20060101 H01H083/02 |
Claims
1. A circuit breaker for an electric load, said circuit breaker
comprising: a plurality of first terminals; a plurality of second
terminals; a number of first separable contacts each of which is
electrically connected between one of said first terminals and one
of said second terminals; a first mechanism structured to open,
close or trip open said number of first separable contacts; a
number of second separable contacts each of which is electrically
connected in series with a corresponding one of said number of
first separable contacts and electrically connected between one of
said first terminals and one of said second terminals; a second
mechanism structured to open or close said number of second
separable contacts; a processor structured to cause said second
mechanism to open or close said number of second separable
contacts, annunciate through one of said second terminals a power
circuit electrical parameter for said electric load, receive from a
number of said second terminals a confirmation from or on behalf of
said electric load to cause said second mechanism to close said
number of second separable contacts, and determine a fault state
operatively associated with current flowing through said number of
second separable contacts.
2. The circuit breaker of claim 1 wherein one of said second
terminals receives a remote reset input; wherein said processor
inputs said remote reset input; and wherein when said remote reset
input is active, said processor causes said second mechanism to
close said number of second separable contacts after receiving said
confirmation from or on behalf of said electric load.
3. The circuit breaker of claim 1 wherein one of said second
terminals receives an output from said processor; and wherein said
processor is structured to determine if said output from said
processor is momentarily electrically disconnected from and then
electrically reconnected to a remote load and responsively cause
said second mechanism to close said number of second separable
contacts after receiving said confirmation from or on behalf of
said electric load.
4. The circuit breaker of claim 3 wherein said output from said
processor is a pulse width modulated signal.
5. The circuit breaker of claim 1 wherein said processor is
structured to determine a fault state and responsively cause said
second mechanism to open said number of second separable contacts;
wherein one of said second terminals receives an output from said
processor; and wherein said processor is structured to determine if
said output from said processor is momentarily electrically
disconnected from and then electrically reconnected to a remote
load and responsively cause said second mechanism to close said
number of second separable contacts if said fault state is
active.
6. The circuit breaker of claim 1 wherein one of said second
terminals receives a proximity input to said processor; and wherein
said processor is structured to determine if said proximity input
is momentarily electrically disconnected from and then electrically
reconnected to a remote load and responsively cause said second
mechanism to close said number of second separable contacts after
receiving said confirmation from or on behalf of said electric
load.
7. The circuit breaker of claim 1 wherein one of said first
terminals is a ground; and wherein one of said second terminals is
said ground.
8. The circuit breaker of claim 1 wherein one of said second
terminals is a proximity input to said processor to indicate that
said electric load is electrically connected to said number of
second separable contacts and to a corresponding number of said
second terminals.
9. The circuit breaker of claim 1 wherein said processor further
comprises a remote communications circuit.
10. The circuit breaker of claim 1 wherein said processor further
comprises a test/reset input structured to cause said processor to
test said second mechanism or to cause said second mechanism to
close said number of second separable contacts.
11. The circuit breaker of claim 1 wherein said processor further
comprises an alternating current to direct current power supply
powered from said first terminals.
12. The circuit breaker of claim 1 wherein said processor further
comprises a number of indicators structured to indicate at least
one of a fault state determined by said processor and current
flowing through said number of second separable contacts.
13. The circuit breaker of claim 1 wherein said first mechanism
comprises a thermal-magnetic trip mechanism.
14. The circuit breaker of claim 1 wherein said first terminals
comprise a first line input and one of a second line input and a
neutral; and wherein said second terminals comprise a first load
output and one of a second load output and a load neutral.
15. The circuit breaker of claim 1 wherein said processor and said
second mechanism cooperate to provide a ground fault trip
mechanism.
16. The circuit breaker of claim 15 wherein one of said second
terminals is electrically connected to a conductor having a pilot
signal output by said processor to annunciate the maximum value of
current permitted to flow through said number of second separable
contacts and input by said processor to receive the confirmation
from or on behalf of said electric load to cause said second
mechanism to close said number of second separable contacts;
wherein said processor is further structured to determine a fault
state responsive to a ground fault detected by said ground fault
trip mechanism or a pilot error operatively associated with said
pilot signal and responsively cause said second mechanism to open
said number of second separable contacts; and wherein said
processor is further structured to cause said second mechanism to
reclose said number of second separable contacts after a
predetermined time.
17. The circuit breaker of claim 1 wherein one of said second
terminals receives an output from said processor; and wherein said
processor is structured to determine if said output from said
processor is momentarily electrically disconnected from and then
electrically reconnected to a remote load and responsively cause
said second mechanism to close said number of second separable
contacts after receiving said confirmation from or on behalf of
said load.
18. The circuit breaker of claim 1 wherein one of said second
terminals receives an output from said processor; and wherein said
processor is structured to determine if said output from said
processor is momentarily electrically disconnected from and then
electrically reconnected to a remote resistance of said load and
responsively cause said second mechanism to close said number of
second separable contacts after receiving said confirmation from or
on behalf of said load.
19. The circuit breaker of claim 1 wherein one of said second
terminals receives a proximity input to said processor; and wherein
said processor is structured to determine if said proximity input
is momentarily electrically disconnected from and then electrically
reconnected to a remote resistance of said load and responsively
cause said second mechanism to close said number of second
separable contacts after receiving said confirmation from or on
behalf of said load.
21. A power vending circuit breaker for an electric load, said
power vending circuit breaker comprising: a plurality of first
terminals; a plurality of second terminals; a number of separable
contacts, at least one of said number of separable contacts being
electrically connected between one of said first terminals and one
of said second terminals; a thermal-magnetic protection circuit
electrically connected in series with said at least one of said
number of separable contacts between said one of said first
terminals and said one of said second terminals; a metering circuit
within said power vending circuit breaker and operatively
associated with power flowing through said at least one of said
number of separable contacts between said one of said first
terminals and said one of said second terminals; a mechanism
structured to open or close said number of separable contacts; a
processor within said power vending circuit breaker and structured
to cause said mechanism to open or close said number of separable
contacts, to input a plurality of power values from said metering
circuit and to determine a plurality of energy values; and a
communication mechanism cooperating with said processor to
communicate said energy values to a remote location.
22. The power vending circuit breaker of claim 21 wherein said
number of separable contacts comprises a plurality of sets of
separable contacts; wherein said at least one of said number of
separable contacts is a first one of said sets of separable
contacts; and wherein said metering circuit comprises a first
current sensor electrically connected in series with said first one
of said sets of separable contacts between said one of said first
terminals and said one of said second terminals, a second current
sensor electrically connected in series with a second one of said
sets of separable contacts between another one of said first
terminals and another one of said second terminals, a first voltage
sensor sensing a first voltage operatively associated with said
first one of said sets of separable contacts, a second voltage
sensor sensing a second voltage operatively associated with said
second one of said sets of separable contacts, and a power metering
circuit cooperating with said first and second current sensors and
said first and second voltage sensors to provide the plurality of
power values to said processor.
23. The power vending circuit breaker of claim 21 wherein said
communication mechanism includes an expansion port communicating
with a number of add-on modules.
24. The power vending circuit breaker of claim 23 wherein said
electric load is an electric vehicle; and wherein said number of
add-on modules is an electric vehicle add-on module interfacing
said electric vehicle, said electric vehicle add-on module being
structured to communicate with said electric vehicle, detect a
ground fault in a power circuit between said power vending circuit
breaker and said electric vehicle, and control said plurality of
sets of separable contacts through said expansion port.
25. The power vending circuit breaker of claim 23 wherein said
electric load is an inverter; and wherein said number of add-on
modules is a solar or photovoltaic add-on module interfacing said
inverter.
26. The power vending circuit breaker of claim 25 wherein said
solar or photovoltaic add-on module comprises a communication
circuit interfaced to said expansion port; said communication
circuit including a first communication port structured to
interface said inverter and a second communication port structured
to interface an electric utility.
27. The power vending circuit breaker of claim 23 wherein said
electric load is HVAC equipment; and wherein said number of add-on
modules is an HVAC add-on module interfacing said HVAC equipment,
said HVAC add-on module comprising a communication circuit
interfaced to said expansion port, a wireless communication circuit
interfaced to said communication circuit, a thermostat, a plurality
of solid state relays, a plurality of terminals for HVAC signals
driven by said solid state relays, and a processor cooperating with
said communication circuit, said thermostat and said solid state
relays to control and monitor said HVAC equipment.
28. The power vending circuit breaker of claim 23 wherein said
number of add-on modules is a plurality of add-on modules
comprising a first add-on module and a second add-on module, said
first add-on module comprising a communication circuit interfaced
to said expansion port, said second add-on module being interfaced
to said first add-on module.
29. The power vending circuit breaker of claim 28 wherein said
electric load is an electric vehicle; wherein said first add-on
module is an electric vehicle add-on module interfacing said
electric vehicle, said electric vehicle add-on module being
structured to communicate with said electric vehicle, detect a
ground fault in a power circuit between said power vending circuit
breaker and said electric vehicle, and control said plurality of
sets of separable contacts through said expansion port; and wherein
said second add-on module is an RFID authentication add-on module
structured to authenticate a user operatively associated with said
electric vehicle.
30. The power vending circuit breaker of claim 23 wherein said
power vending circuit breaker is a two-pole circuit breaker; and
wherein said number of add-on modules is a two-pole add-on module
coupled to one end of said two-pole circuit breaker or coupled to
one side of said two-pole circuit breaker with a plurality of
jumpers therebetween.
31. The power vending circuit breaker of claim 23 wherein said
expansion port is a first expansion port comprising a plurality of
conductors for a serial communication interface between said first
expansion port and said add-on module, signal ground, neutral,
control power, status of said power vending circuit breaker, and
control of said number of separable contacts.
32. A circuit breaker for an electric load, said circuit breaker
comprising: a plurality of first terminals; a plurality of second
terminals; a number of separable contacts each of which is
electrically connected between one of said first terminals and one
of said second terminals; a mechanism structured to open or close
said number of separable contacts; and a processor structured to
cause said mechanism to open or close said number of separable
contacts, annunciate through one of said second terminals a power
circuit electrical parameter for said electric load, receive from a
number of said second terminals a confirmation from or on behalf of
said electric load to cause said mechanism to close said number of
separable contacts, and determine a fault state operatively
associated with current flowing through said number of separable
contacts.
33. The circuit breaker of claim 32 wherein said first terminals
include a line terminal and a neutral terminal; and wherein said
number of separable contacts are two sets of separable contacts;
wherein said second terminals include a load terminal and a load
neutral terminal; wherein a first set of said two sets of separable
contacts is electrically connected between said line terminal and
said load terminal; and wherein a second set of said two sets of
separable contacts is electrically connected between said neutral
terminal and said load neutral terminal.
34. The circuit breaker of claim 32 wherein a fuse is electrically
connected in series with one of said number of separable contacts;
and wherein each of said number of separable contacts is a solid
state switching device.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is related to commonly assigned, copending
U.S. patent application Ser. No. ______, filed ______, entitled
"Electric Power Distribution System Including Metering Function and
Method of Evaluating Energy Metering" (Attorney Docket No.
12-CCB-853).
BACKGROUND
[0002] 1. Field
[0003] The disclosed concept pertains generally to electrical
switching apparatus and, more particularly, to circuit
breakers.
[0004] 2. Background Information
[0005] Circuit breakers used in residential and light commercial
applications are commonly referred to as miniature circuit breakers
because of their limited size. Such circuit breakers typically have
a pair of separable contacts opened and closed by a spring biased
operating mechanism. A thermal-magnetic trip device actuates the
operating mechanism to open the separable contacts in response to a
persistent overcurrent condition or a short circuit.
[0006] In some applications, it has been found convenient to use
circuit breakers for other purposes than just protection, for
instance, for load shedding. It is desirable to be able to perform
this function remotely, and even automatically, such as under the
control of a computer. However, the spring biased operating
mechanisms are designed for manual reclosure and are not easily
adapted for reclosing remotely. In any event, such operating
mechanisms are not designed for repeated operation over an extended
period of time.
[0007] Remotely controllable circuit breakers or remotely operated
circuit breakers introduce a second pair of separable contacts in
series with the main separable contacts. See, for example, U.S.
Pat. Nos. 5,301,083; 5,373,411; 6,477,022; and 6,507,255. The main
contacts still interrupt the overcurrent, while the secondary
contacts perform discretionary switching operations. For example,
the secondary contacts are controlled by a solenoid, which is
spring biased to close the contacts, or by a latching solenoid.
[0008] Conventional ground fault circuit breakers provide ground
fault detection and thermal-magnetic overload sections that are
coupled with a single circuit breaker operating handle to indicate
on, tripped and off states, and to control opening and closing of
the power circuit.
[0009] An electric vehicle (EV) charging station, also called an EV
charging station, electric recharging point, charging point, and
EVSE (Electric Vehicle Supply Equipment), is an element in an
infrastructure that supplies electric energy for the recharging of
electric vehicles, plug-in hybrid electric-gasoline vehicles, or
semi-static and mobile electrical units such as exhibition
stands.
[0010] An EV charging station is a device that safely allows
electricity to flow. These charging stations and the protocols
established to create them are known as EVSE, and they enhance
safety by enabling two-way communication between the charging
station and the EV.
[0011] The 1996 NEC Article 625 defines EVSE as being the
conductors, including the ungrounded, grounded, and equipment
grounding conductors, the EV connectors, attachment plugs, and all
other fittings, devices, power outlets or apparatus installed
specifically for the purpose of delivering energy from premises
wiring to an EV.
[0012] EVSE is defined by the Society of Automotive Engineers (SAE)
recommended practice J1772.TM. and the National Fire Protection
Association (NFPA) National Electric Code (NEC) Article 625. While
the NEC defines several safety requirements, J1772.TM. defines the
physical conductive connection type, five pin functions (i.e., two
power pins (Hot1 and Hot2 or neutral; or Line 1 and Line 2), one
ground pin, one control pilot pin, and one proximity pin), the EVSE
to EV handshake over the pilot pin, and how both parts (EVSE and
EV) are supposed to function.
[0013] Two-way communication seeks to ensure that the current
passed to the EV is both below the limits of the EV charging
station itself, below the limits of the cordset connecting the EV
charging station to the EV, and below the tripping limit of
upstream protection devices, such as circuit breakers. The EV is
the load and the load dictates how much power is being pulled. The
EV knows its own limits and since it sets the amount of current
being pulled, communication is not required in order to protect the
EV. Instead, communication is employed to protect all of the
distribution equipment delivering power to the EV.
[0014] There are additional safety features, such as a load
interlock, that does not allow current to flow from the EV charging
station until the EV connector or EV plug is physically inserted
into the EV and the EV is ready to accept energy. Once the EV
signals that it is finished accepting energy or the EV is
unplugged, the load interlock continues to prevent current
flow.
[0015] SAE J1772.TM. in the United States and the IEC 61851
standard in the rest of the world or where applicable use a very
simple but effective pilot circuit and handshake in the EVSE. For
charging a vehicle using alternating current (AC), basically a
signal is generated on the pilot pin, starting at a constant +12
Vdc open circuit when measured to the ground pin. When the EVSE
cable and connector is plugged into an EV inlet of a compliant
vehicle, the vehicle's circuit has a resistor and a diode in series
that ties to ground in order to drop the +12 Vdc to +9 Vdc. After
the EVSE sees this drop in voltage, it turns on a pulse-width
modulated (PWM) generator that defines the maximum available line
current (ALC) on the charging circuit. This generated PWM signal
oscillates between +12 Vdc and -12 Vdc when measured at its source.
The vehicle charge controller reads the percentage of the duty
cycle of the PWM signal, which is equivalent to a set amperage, and
sets the maximum current draw on the onboard vehicle
rectifier/charger, in order to not trip an upstream circuit
interrupter, such as a circuit breaker. The vehicle, in turn, adds
another resistor in parallel with the resistor of the vehicle's
resistor and diode series combination, which then drops the top
level of the PWM pilot signal to +6 Vdc while leaving the bottom
level at -12 Vdc. This tells the EVSE that the vehicle is ready to
charge and that it is actually a vehicle and not simply a
resistance such as a person's finger which caused the voltage drop.
In response, the EVSE closes an internal relay/contactor to allow
AC power to flow to the vehicle.
[0016] Known EV charging stations consist generally of a completely
separate device from a load center, panelboard, or normal upstream
protection. Such EV charging stations are a special box with
indicators for power and state along with a connected EV
cable/connector for the intended purpose of charging the EV. These
EV charging stations require an upstream circuit breaker, and a
completely separate, special enclosure and an EV
cable/connector.
[0017] Electric utilities desire to separately meter and bill power
going to an EV or other electric loads deemed applicable by the
utility or other authority. Known methods require a separately
derived metering system, which is relatively expensive and complex
to install and manage. This prohibits technology adoption and
implementation. There is room for improvement in sub-metering,
billing against, and managing electric loads deemed "special" or
otherwise applicable by electric utilities or other
authorities.
[0018] There is room for improvement in circuit breakers and EV
charging stations.
SUMMARY
[0019] These needs and others are met by various embodiments of the
disclosed concept in which a circuit breaker processor annunciates
a power circuit electrical parameter for an electric load (e.g.,
without limitation, an electric vehicle), receives a confirmation
from or on behalf of the electric load to cause a mechanism to
close the separable contacts, and determines a fault state
operatively associated with current flowing through the separable
contacts.
[0020] In accordance with one aspect of the disclosed concept, a
circuit breaker for an electric load comprises a plurality of first
terminals; a plurality of second terminals; a number of first
separable contacts each of which is electrically connected between
one of the first terminals and one of the second terminals; a first
mechanism structured to open, close or trip open the number of
first separable contacts; a number of second separable contacts
each of which is electrically connected in series with a
corresponding one of the number of first separable contacts and
electrically connected between one of the first terminals and one
of the second terminals; a second mechanism structured to open or
close the number of second separable contacts; a processor
structured to cause the second mechanism to open or close the
number of second separable contacts, annunciate through one of the
second terminals a power circuit electrical parameter for the
electric load, receive from a number of the second terminals a
confirmation from or on behalf of the electric load to cause the
second mechanism to close the number of second separable contacts,
and determine a fault state operatively associated with current
flowing through the number of second separable contacts.
[0021] As another aspect of the disclosed concept, a power vending
circuit breaker for an electric load comprises: a plurality of
first terminals; a plurality of second terminals; a number of
separable contacts, at least one of the number of separable
contacts being electrically connected between one of the first
terminals and one of the second terminals; a thermal-magnetic
protection circuit electrically connected in series with the at
least one of the number of separable contacts between the one of
the first terminals and the one of the second terminals; a metering
circuit within the power vending circuit breaker and operatively
associated with power flowing through the number of separable
contacts between the one of the first terminals and the one of the
second terminals; a mechanism structured to open or close the
number of separable contacts; a processor within the power vending
circuit breaker and structured to cause the mechanism to open or
close the number of separable contacts, to input a plurality of
power values from the metering circuit and to determine a plurality
of energy values; and a communication mechanism cooperating with
the processor to communicate the energy values to a remote
location.
[0022] As another aspect of the disclosed concept, a circuit
breaker for an electric load comprises: a plurality of first
terminals; a plurality of second terminals; a number of separable
contacts each of which is electrically connected between one of the
first terminals and one of the second terminals; a mechanism
structured to open or close the number of separable contacts; and a
processor structured to cause the mechanism to open or close the
number of separable contacts, annunciate through one of the second
terminals a power circuit electrical parameter for the electric
load, receive from a number of the second terminals a confirmation
from or on behalf of the electric load to cause the mechanism to
close the number of separable contacts, and determine a fault state
operatively associated with current flowing through the number of
separable contacts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] A full understanding of the disclosed concept can be gained
from the following description of the preferred embodiments when
read in conjunction with the accompanying drawings in which:
[0024] FIG. 1 is a block diagram of an electric vehicle (EV)
circuit breaker in accordance with embodiments of the disclosed
concept.
[0025] FIG. 2 is a block diagram of a single-phase, two-line,
double-pole EV circuit breaker in accordance with another
embodiment of the disclosed concept.
[0026] FIG. 3 is a block diagram of a three-phase, three-pole EV
circuit breaker in accordance with another embodiment of the
disclosed concept.
[0027] FIGS. 4A-4B form a block diagram of an EV circuit breaker,
EVSE connector, and EV in accordance with another embodiment of the
disclosed concept.
[0028] FIG. 5 is a flowchart of a test/reset routine of the EV
circuit breaker of FIGS. 4A-4B.
[0029] FIG. 6 is a flowchart of a top level routine of the EV
circuit breaker of FIGS. 4A-4B.
[0030] FIG. 7 is a flowchart of a proximity logic routine of the EV
circuit breaker of FIGS. 4A-4B.
[0031] FIG. 8 is a flowchart of a ground fault detection routine of
the EV circuit breaker of FIGS. 4A-4B.
[0032] FIG. 9 is a flowchart of a fault and lockout logic routine
of the EV circuit breaker of FIGS. 4A-4B.
[0033] FIG. 10 is a plot of ground fault tripping time versus
current for the EV circuit breaker of FIGS. 4A-4B.
[0034] FIG. 11 is a simplified block diagram of a single-phase
power vending machine (PVM) circuit breaker in accordance with
another embodiment of the disclosed concept.
[0035] FIG. 12 is a relatively more detailed block diagram of the
PVM circuit breaker of FIG. 11.
[0036] FIG. 13 is a further simplified block diagram of the PVM
circuit breaker of FIG. 11.
[0037] FIG. 14 is a relatively more detailed block diagram of the
EV add-on module of FIG. 11.
[0038] FIG. 15 is a block diagram of a solar or photovoltaic (PV)
add-on module in accordance with another embodiment of the
disclosed concept.
[0039] FIG. 16 is a block diagram of an HVAC add-on module in
accordance with another embodiment of the disclosed concept.
[0040] FIG. 17 is a block diagram of a general purpose input/output
(I/O) add-on module in accordance with another embodiment of the
disclosed concept.
[0041] FIGS. 18A-18C are simplified plan views of circuit breakers
and add-on modules in accordance with other embodiments of the
disclosed concept.
[0042] FIG. 19 is a block diagram of a PVM system including a main
circuit breaker, which functions as or in conjunction with a local
controller and gateway, and a plurality of PVM circuit breakers and
add-on modules in accordance with another embodiment of the
disclosed concept.
[0043] FIG. 20 is an exploded isometric view of a circuit breaker
and add-on module in accordance with another embodiment of the
disclosed concept.
[0044] FIG. 21 is a block diagram of a PVM circuit breaker
including a single set of separable contacts per power conductor
and a fuse in accordance with another embodiment of the disclosed
concept.
[0045] FIG. 22 is a block diagram of a PVM circuit breaker
including a single set of separable contacts per power conductor in
accordance with another embodiment of the disclosed concept.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0046] As employed herein, the term "number" shall mean one or an
integer greater than one (i.e., a plurality).
[0047] As employed herein, the term "processor" shall mean a
programmable analog and/or digital device that can store, retrieve,
and process data; a computer; a workstation; a personal computer; a
microprocessor; a microcontroller; a microcomputer; a central
processing unit; a mainframe computer; a mini-computer; a server; a
networked processor; control electronics; a logic circuit; or any
suitable processing device or apparatus.
[0048] As employed herein, the statement that two or more parts are
"connected" or "coupled" together shall mean that the parts are
joined together either directly or joined through one or more
intermediate parts. Further, as employed herein, the statement that
two or more parts are "attached" shall mean that the parts are
joined together directly.
[0049] The disclosed concept is described in association with
circuit breakers having one, two or three poles for electric loads,
although the disclosed concept is applicable to a wide range of
circuit breakers having any suitable number of poles for a wide
range of electric loads (e.g., without limitation, electric
vehicles).
[0050] Referring to FIG. 1, a load annunciating circuit breaker 2
is shown. The circuit breaker 2, which can be used in connection
with an electric vehicle (EV) 4 (shown in phantom line drawing),
includes: a thermal-magnetic overload circuit breaking function 6,
a charging circuit interrupting device (CCID) function 8, and a
load annunciation function, such as the example EV interlock
function 10. The circuit breaker 2 includes input terminals for
line (L) 12, neutral (N) 14 and ground (G) 16 and output terminals
for the load (e.g., hot/line) 18 and load neutral (e.g., neutral)
20.
Example 1
[0051] The circuit breaker 2 can, for example and without
limitation, charge the example EV 4 using SAE J1772.TM., but can
also provide a controllable point to provide more general power
vending capabilities as will be discussed in connection with FIGS.
11-13. The circuit breaker 2 can be controlled by onboard, add-on,
or remote software conditionals (see Example 28), rather than
simply employing an open/close signal such as with a conventional
remotely controllable circuit breaker.
Example 2
[0052] The example circuit breaker 2 can employ any suitable form
factor (e.g., without limitation, a miniature circuit breaker; a
molded case circuit breaker; any other suitable circuit interrupter
form factor). In this example, the circuit breaker 2 is a
single-pole circuit breaker. In territories where IEC is required,
a single-pole circuit breaker may be employed (e.g., in a DIN rail
mountable form factor).
Example 3
[0053] Although the circuit breaker 2 could be constructed with
only one circuit breaking element per conductor as will be
discussed in connection with FIG. 22, the example thermal-magnetic
overload circuit breaking function 6 is separated from the CCID
function 8, which provides personnel protection for EVSE
applications.
[0054] For example, for the EV 4, the CCID function 8 continuously
monitors the differential current from a ground fault sensor (e.g.,
current transformer (CT) 52) among all of the current-carrying
conductors in a grounded system and rapidly interrupts the circuit
under conditions where the differential current exceeds the rated
value (e.g., without limitation, 5 mA; 20 mA) of the charging
circuit interrupting device. The CCID function 8 may include any
suitable combination of basic insulation, double insulation,
grounding monitors, insulation monitors with interrupters,
isolation monitoring (depending on whether it is grounded or not)
and/or leakage current monitors. Alternatively, for non-EV load
applications, a GFCI function can be provided with either personnel
protection or equipment protection.
Example 4
[0055] The example EV interlock function 10: (1) controls the CCID
function 8; (2) generates and monitors the example pilot signal 22
(FIG. 4A), which serves as the annunciator to the load (e.g.,
without limitation, the example pilot signal 22 annunciates a
certain amount of permitted current flow to the EV 4 and receives
confirmation from or on behalf of (e.g., an agent acting on behalf
of (e.g., an independent supervisory control system) the EV 4) the
EV 4 of its current state back to the circuit breaker 2' (FIGS.
4A-4B)); (3) creates an "interlock" based on the pilot signal 22
"handshake" state between the circuit breaker 2 and the compatible
downstream EV 4 (e.g., the separable contacts 24 of the CCID
function 8 do not close and provide power to the EV 4 until the
proper state is achieved, and open to stop power flow if a fault
occurs); (4) receives signals from the CCID function 8 on whether
it is detecting a fault condition; and (5) inputs (e.g., a wire
termination point 26 of an EVSE connector 28 (FIG. 4B) for the
pilot signal 22 to annunciate the state to the EV 4 and receive the
state from the EV 4.
[0056] Alternatively, rather than annunciating a maximum value of
current permitted (e.g., available line current (ALC)) to flow
through the separable contacts 24 to the electric load (e.g., the
EV 4), this can annunciate a maximum and/or a minimum value of
voltage permitted to be applied through the separable contacts 24
to the electric load, a direction (i.e., forward or reverse) of
power flow through the separable contacts 24 to or from the
electric load, a minimum power factor permitted for the electric
load, and a minimum conversion efficiency permitted by the electric
load.
Example 5
[0057] The example EV interlock function 10 can provide one or more
of the following optional functions: (1) other metering,
allocation, authentication, communication and/or additional
protective functionality may be employed in or with the circuit
breaker 2 (see, for example, Examples 20-24); (2) another wire
termination point 30 is employed by the EVSE connector 28 (FIG. 4B)
and vehicle inlet 32 to announce its proximity and successful
locking into a receptacle (e.g., 28 of FIG. 4B); (3) additional
logic to handle proximity as used in the IEC standard to further
restrict when the interlock is allowed to close and the amount of
current allowed by the circuit breaker 2 (e.g., cable proximity
wire sensing is shown in connection with FIG. 7); (4) resetting
(i.e., reclosing) automatically after a predetermined time on a
detected fault, specifically a ground fault or pilot error (e.g.,
automatic reclosure is shown in connection with FIG. 6); and (5)
varying the ground fault tripping time based on current and the
amount of time within the handshake state (e.g., as shown in
connection with FIGS. 8 and 10, the circuit breaker 2 does not trip
immediately on closure if it ground faults immediately due to the
possibility of ground leakage (e.g., arising from inrush current,
charging capacitors or inductors); the circuit breaker 2 may allow
some ground leakage current and vary its trip time while staying
below the plot of current versus time; for a fault condition of 20
mA to 100 mA, the response time is less than or equal to 100 mS,
for a fault condition of 100 mA to 308 mA, the response time (T) is
less than or equal to (20/T).sup.1.43 mS, and for a fault condition
of greater than 308 mA, the response time is less than or equal to
20 mS).
Example 6
[0058] The optional SAE J1772.TM. pilot signal specification for
the pilot signal 22 is one example way to achieve the
annunciator/interlock functions. A generator/monitor or other
suitable communications path (e.g., without limitation, an optional
power line carrier (PLC)), can be employed to form a similar, but
different, encoding of information to: (a) communicate available
line current (of the power circuit) as determined by the rating of
the components or a controller; (b) communicate
readiness/state/condition (of the circuit breaker 2 or EV 4); (c)
communicate protective functions (of the circuit breaker 2 or EV
4); and/or (d) communicate load characteristics back to the circuit
breaker 2 (or EV 4). The communication can provide, for example and
without limitation, a power vending (e.g., power metering,
delivery, control, and management) capability (Examples 20-24) with
annunciation and interlocking from a circuit breaker, such as 2, to
a load, such as the EV 4. This replaces the pilot signal 22 with
digital communications over a power line, device to device.
Example 7
[0059] For example, for the interlock of the third option of
Example 4, the interlock does not close the protected power circuit
until a resistor value is read. The resistor's value represents
different current ratings predefined in a corresponding industry
standard. As a more specific example, the IEC method for charging
EVs has a detachable cable with EV connectors on both sides. Each
EV connector has a resistor tied from proximity (e.g., 36 of FIG.
4B) to ground that matches the rated current carrying capability of
the cable. For example, if a 12 A cable was connected to a 16 A
EVSE, and then connected to an EV capable of pulling 30 A, the EVSE
lowers its PWM duty cycle from corresponding to the usual 16 A to
correspond to 12 A, which is then transmitted to the EV, which
thereby causes the EV to only pull a maximum of 12 A. This ensures
that the system takes the lowest rating of all components to ensure
safety and keep the equipment within its rated limits.
Example 8
[0060] For example, for the second option of Example 4, the circuit
breaker 2 includes a termination point 34 (FIG. 4A) for the
proximity circuit conductor 36 from the EVSE connector 28 (FIG.
4B). For example, this can monitor the pressing of a release latch,
or this same proximity circuit can also be overridden as a method
for input--specifically used for resetting a fault by monitoring
the proximity circuit value in conjunction with the pilot circuit.
Using the knowledge that the EV cable is still connected by the
state of the pilot signal 22, if the proximity circuit goes open
circuit, then that can be interpreted as being a reset command
without any additional conductors or communication. Alternatively,
the conductor 36 can be electrically connected to a remote reset
button (not shown).
[0061] By employing an EV connector latch button as a reset by
monitoring the proximity conductor 36, the circuit breaker 2 can be
programmed, in order that when a button is pressed, the proximity
circuit is opened and the circuit breaker 2 performs the same
function as if a local test/reset button 46 (FIG. 4A) has been
pressed.
Example 9
[0062] The circuit breaker 2 can include a local indication of
state through a suitable indicator (e.g., without limitation,
indication light; LED; color; flag). Example states include ready,
charging, and trouble. As shown in FIG. 4A, the ready indicator 38
(e.g., AC present) is on anytime the circuit breaker separable
contacts 48' are closed and can supply power. The charging
indicator 40 is an interlock indicator and is on anytime the
contacts 24' of contactor/relay 44 are closed and power is
available at the EVSE connector 28 (FIG. 4B). The trouble indicator
42 is illuminated anytime the circuit breaker 2' has entered a
fault state. Additionally, different blink patterns may be employed
to provide additional user interface feedback. For example, the
trouble indicator 42 could have a certain blink pattern to tell
what exact fault occurred.
Example 10
[0063] The circuit breaker 2' of FIGS. 4A-4B can include a local
input 46 to test and reset (e.g., without limitation, a button on
the circuit breaker 2'). As will be described in connection with
FIG. 5, a test leaks a relatively small, known current to ground
and verifies that a ground fault detection circuit is properly
working. The test is only done while the power circuit is open. The
test is generally done right before the contactor/relay 44 is
closed and should be open throughout the test. If the test fails,
then it prevents the contactor/relay 44 from closing. This test is
only done to ensure that the circuit breaker 2' can still detect a
ground fault in a safe to the user situation. If the power circuit
is closed, then the circuit breaker 2' is still monitoring for
ground fault but never injecting current. For a manual test (by
pressing the button), the power circuit is opened, the test is
performed, and then normal operation is resumed if the test passes.
Regardless of the test passing or failing, the contactor/relay 44
should be open on its completion. If the test fails, then the
circuit breaker 2' remains open and enters a service state where
the relay 44 cannot be reset by pressing the test/reset button 46
again. The button 46 will always perform its "test" functionality
unless the EV 4 is connected and the contactor/relay 44 is open
from an actual fault or a previous test. In this case, the "reset"
functionality will be performed and the contactor/relay 44 will be
closed.
Example 11
[0064] The thermal-magnetic overload circuit breaking function 6 of
FIG. 1 includes first separable contacts 48 and a thermal and
magnetic overload protection mechanism 50. The CCID function 8
includes the second separable contacts 24, the CT 52 and a
processor (e.g., .mu.C or control electronics 68), preferably with
customizable trip settings, which receives the differential current
signal 53 from CT 52 and controls the second separable contacts 24
with a control signal 54. The .mu.C or control electronics 68 is
used by both of the CCID function 8 and the example EV interlock
function 10. The neutral (N) 14 is input by a neutral pigtail 56.
The example EV interlock function 10 inputs the ground (G) 16 by a
ground pigtail 58, and includes pulse width modulation (PWM)
generation and sensing logic 60 and the termination point 26 for
the pilot signal 22.
Example 12
[0065] FIGS. 2 and 4A-4B show the single-phase, two-line,
double-pole circuit breaker 2', which can be used in connection
with the EV 4. The circuit breaker 2' includes a double-pole
thermal-magnetic overload circuit breaking function 6', a
double-pole CCID function 8', and the example EV interlock function
10. The circuit breaker 2' further includes inputs for two lines L1
12' and L2 12'', and ground (G) 16, and output terminations for the
load (e.g., hot/line 1 18 and hot/line 2 20). In this example, a
neutral is not employed. Control electronics 68 are powered by an
alternating current to direct current power supply 69 (FIG.
4A).
[0066] For the double-pole thermal-magnetic overload circuit
breaking function 6', thermal-magnetic devices are employed on any
hot or ungrounded conductors coming into the circuit breaker 2'. In
contrast, for the single-pole circuit breaker 2 of FIG. 1 with line
(L) 12 and neutral (N) 14 terminations, the single thermal-magnetic
device 50 is employed. For example, for the overcurrent
thermal-magnetic device, this is rated 125% of the maximum
continuous load, or whatever is required by local codes and
standards, the circuit breaker 2 will supply (e.g., without
limitation, a 40 A circuit breaker for a 32 A EVSE).
[0067] The double-pole CCID function 8' of FIG. 2 can employ a
double-pole relay 44 as shown in FIG. 4A. The relay 44 can be a
digitally controlled circuit breaking rated relay or contactor. The
double-pole relay 44 is employed on any hot or ungrounded
conductors coming into the circuit breaker 2'. In contrast, for the
single-pole circuit breaker 2 of FIG. 1 with line (L) 12 and
neutral (N) 14 terminations, a single-pole relay is employed.
Otherwise, the circuit breaker 2' is generally similar to the
circuit breaker 2 of FIG. 1.
Example 13
[0068] FIG. 3 shows a three-phase, three-pole circuit breaker 2'',
which can be used in connection with a suitable EV (not shown). The
circuit breaker 2'' includes a three-pole thermal-magnetic overload
circuit breaking function 6'', a three-pole CCID function 8'', and
the example EV interlock function 10. The circuit breaker 2''
further includes inputs for three phases A 12A, B 12B and C 12C,
ground (G) 16 and neutral (N) 14, and output terminations
18A,18B,18C for the three-phase load. Otherwise, the circuit
breaker 2'' is generally similar to the circuit breaker 2 of FIG.
1.
Example 14
[0069] FIGS. 4A-4B show a more detailed version of the circuit
breaker 2' of FIG. 2 including the EVSE connector 28 having a
ground pin 16', a pilot pin 26 and a proximity pin 30, and the EV
4. As is conventional, a conductor 62 passes through current
transformer 64 and mimics leakage of ground current in connection
with the performance of ground fault self-check tests. The
test/reset button 46 effectively functions as a test/clear
temporary fault button, with possible support for clearing a
lockout or rebooting by being actuated for a predetermined period
of time.
[0070] The circuit breaker 2' can support the following example
fault categories: (1) circuit breaker trip; (2) permanent fault;
(3) lockout fault; and (4) temporary fault. Each example fault also
has a corresponding reset: (1) reset the physical circuit breaker
operating handle 66; (2) reboot the software of the control
electronics 68; (3) clear a lockout fault; and (4) clear a
temporary fault.
[0071] Resetting the circuit breaker operating handle 66 reboots
the software, clears a lockout, and clears a temporary fault.
Rebooting the software clears a lockout, and clears a temporary
fault. Clearing a lockout also clears a temporary fault. Unplugging
the load (e.g., the EV 4) also clears a lockout and clears a
temporary fault.
[0072] The thermal-magnetic overload circuit breaking function 6'
faults in a conventional manner by tripping open the two example
separable contacts 48' and the circuit breaker operating handle 66
in response to a short circuit or other overload current
condition.
[0073] The relay 44 can trip for any of the following reasons
(additionally, for example and without limitation, it can detect
arc faults) in Table 1:
TABLE-US-00001 TABLE 1 Fault No. Fault Fault Category 0 "No Fault"
No fault since last boot 1 "Pilot Error During Idle" Temporary 2
"Pilot Error During Run" Temporary 3 "Ground Fault Detected"
Temporary 4 "Overcurrent Detected" Temporary 5 "Break Away
Occurred" Permanent 6 "Temporary Fault Lockout Fault Lockout
Occurred (Reset with Plug Session Cycle)" 7 "Ground Impedance
Permanent Fault" 8 "Contactor Fault" Permanent 9 "Ground Fault Test
Permanent or Temporary, Failure" depending if the load is connected
(actual ground fault compared to a self- check test failure) 10
"Diode Fault" Temporary 11 "Master Fault Count Permanent, this
fault count Exceeded (Reset lasts across Plug Sessions Required)"
within a predetermined time period 12 "Firmware Checksum Permanent
Fault" 13 "Calibration Invalid" Semi-Permanent, after the
calibration settings are set correctly, the EVSE can enter a
Non-Fault State 14 "System Clock Fault" Permanent 16 "Pilot
Frequency Out of Temporary Tolerance" 17 "System Resources
Temporary Unavailable" 18 "Excessive Noise on Pilot Temporary
Signal" 19 "Low Line Voltage" Temporary 20 "Watchdog Timer
Permanent Expired"
[0074] Lockout faults are shown in Table 2:
TABLE-US-00002 TABLE 2 Fault No. Lockout Fault 0 "No Fault" 1
"Pilot Error During Idle" 2 "Pilot Error During Run" 3 "Ground
Fault Detected" 4 "Overcurrent Detected" 5 "Break Away Occurred" 6
"Temporary Fault Lockout Occurred (Reset with Plug Session Cycle)"
7 "Ground Impedance Fault (not used)" 8 "Contactor Fault" 9 "Ground
Fault Test Failure" 10 "Diode Fault" 11 "Master Fault Count
Exceeded (Reset Required)" 12 "Firmware Checksum Fault" 13
"Calibration Invalid" 14 "System Clock Fault" 16 "Pilot Frequency
Out of Tolerance" 17 "System Resources Unavailable" 18 "Excessive
Noise on Pilot Signal" 19 "Low Line Voltage"
[0075] EVSE states are shown in Table 3:
TABLE-US-00003 TABLE 3 State No. EVSE State 0 "Power-Up
Initialization" 1 "Idle (Not Connected to EV)" 2 "EVSE in Test
Mode" 3 "EVSE in Demo Mode" 4 "Permissive Run Disabled" (External
Hardware Input or Software Control of EVSE to disable Plug Sessions
from occurring; provides Binary On/Off control 5 "Service Required"
(this Permanent Fault requires reset or repair) 6 "Temporary Fault
Condition" (Lockout or Temporary fault) 7 "EVSE Charging" 8 "EV
Connected - Not Charging" 9 "EV Connected - ALC Charging Disabled"
(external hardware input or software control of EVSE which has
Available Line Current set to 0) 27 "EVSE Deactivated" (external
software control of EVSE to deactivate it and take it out of
service) 28 "Pulse Activation Mode Idle" (similar to Permissive Run
Disabled but uses hardware pulses or a software timer to activate
the EVSE for a predetermined period of time)
Example 15
[0076] FIG. 5 shows a test/reset routine 100 for the control
electronics 68 of the circuit breaker 2' of FIGS. 4A-4B. The
routine 100 begins at 102 in response to the test/reset button 46
being pressed. Next, at 104, it is determined if the circuit
breaker 2' is tripped. If the circuit breaker is not tripped, then
at 106, it is determined if there is a fault state. If there is no
fault state, then at 108, a ground fault test is run along with any
other suitable self-tests. If the ground fault test passes, then it
is determined if a load is connected (i.e., the relay 44 is closed)
at 112. If no load is connected, then a suitable indication is
provided to the user (e.g., without limitation, indication light;
LED; color; flag) that the test was successful at 114. Then, normal
circuit breaker operation resumes at 116. Otherwise, if a load is
connected, then at 118, the test caused an actual ground fault to
occur and the fault routine 500 of FIG. 9 is executed. The reason
that an actual ground fault occurs is because the fault detected
state 217 of FIG. 6 is not suspended during the ground fault test.
This state 217 will correctly detect ground current and cause a
fault to occur. If the ground fault is not detected, then the test
failed at 110 of FIG. 5, and the permanent fault is entered at 126
followed by 124.
[0077] On the other hand, if it is determined that the circuit
breaker is tripped at 104, then the circuit breaker is tripped at
120 (e.g., in response to a short circuit or other overload
condition as shown in FIG. 6). Normal circuit breaker operation is
then resumed at 116 in response to a reset 121 of the circuit
breaker handle 66 of FIG. 4A.
[0078] If it is determined that there is a fault state at 106, then
it is determined if there is a temporary fault state at 122. If the
fault state is not temporary, then there is a permanent fault at
124. Nothing is then done until there is a suitable reset (Example
14), which causes a reboot of the control electronics software at
125 after which normal circuit breaker operation is resumed at
116.
[0079] If it is determined that the test did not pass at 110, then
the permanent fault is entered at 126 followed by 124.
[0080] If there is a temporary fault state at 122, then at 128 it
is determined if a lockout occurred. If so, then a lockout state is
entered at 130 and nothing is done until there is a suitable reset
(Example 14). Normal circuit breaker operation is resumed at 116 in
response to the end of a plug session or lockout is cleared at
131.
[0081] On the other hand, if no lockout occurred at 128, then the
fault is reset at 132 followed by resuming normal circuit breaker
operation at 116.
Example 16
[0082] FIG. 6 shows a top level routine 200 of the circuit breaker
2' of FIGS. 4A-4B, which can implement, for example and without
limitation, SAE J1772.TM.. The routine 200 starts at 202 in
response to a power up condition. Then, self-checks are performed
at 203 as part of a constantly running process 204. If the
self-checks pass at 205, then the routine 200 waits for a load to
connect at 206. When a load is connected at 207, then the
connection is verified at 208. When the connection is verified, a
plug session begins at 209. Next, the available line current (ALC)
is annunciated and the routine 200 waits for the load to indicate
that it is ready to receive power at 210. When the load notifies
that it is ready for power at 211, the routine 200 causes the relay
44 to close and vend or otherwise make power available to the load
at 212. Next, if the load notifies (temporarily) that it is
finished with power, then the contactor/relay 44 is opened again at
210. The ALC never stops being annunciated, unless power is lost, a
fault occurs, or the load is unplugged. Any of 208,210,212,222,224
can transition to 206 in response to the load being unplugged.
[0083] If the self-check 203 fails at 214, then a permanent fault
is entered at 215. The self-check 203 can only be restarted by a
power-up restart at 202, or by a software reboot at 216.
[0084] Also, any of 206,208,210,212 can transition to a fault
detected state 217 in response to detection of a fault. The state
217 determines the fault type at 218. Then, at 219, it is
determined the nature of the fault type. If the fault type is
temporary, then at 220 it is determined if the number of temporary
faults is greater than a lockout limit. If the lockout limit is
reached, then the lockout state is entered at 222. From state 222,
the load is either unplugged or the lockout is cleared at 223 to
re-enter state 206 and wait for the load to connect. Otherwise, if
the lockout limit was not exceeded at 220, then at state 224 a
manual reset or an auto-reclosure is awaited. State 224 is exited
at 226 if the load is unplugged after which state 206 is re-entered
to wait for the load to connect, or at 228 in response to a
temporary fault reset or auto-reclosure after which state 210 is
re-entered to annunciate ALC.
[0085] The control electronics 68 of FIG. 4A include a watchdog
timer (e.g., process 204) to open the contactor/relay 44 and reboot
the software if it becomes unresponsive to provide additional
simultaneous processes to monitor for faults, and to detect when a
load is finished accepting power or unplugs. The control
electronics 68 input the pilot signal 22 through a monitoring
circuit 230, and adjust a PWM signal as part of the pilot signal 22
to the EV 4. The control electronics 68 also open and close the
contactor/relay 44 to provide AC power (L1 and L2 or neutral). The
EV charge controller 232 adjusts a charger 234 to only pull the ALC
as annunciated over the pilot signal 22. The control electronics 68
also output to the indicators 40,42, and communicate through the
communications interface 236.
Example 17
[0086] FIG. 7 shows a proximity logic routine 300 of the control
electronics 68 of the circuit breaker 2' of FIGS. 2 and 4A-4B. In
response to a connection to a vehicle being verified at 209 of FIG.
6, the vehicle connection is determined at 302. Next, it is
determined if a proximity rating is supported at 304 by a
configurable hardware or software setting. If so, then at 306, it
is determined if a proximity rating is detected by determining if
there is a closed circuit resistance from the proximity pin 30 to
ground 16' of FIG. 4B. If so, then the proximity rating is read at
308 by determining the closed circuit resistance and matching this
value with an ampacity in the standard. Then, at 310, the maximum
load annunciation is set to the minimum rated component (e.g., as
is discussed in Example 7). Next, at 312, additional load
verification, such as detecting the EV diode or authenticating the
user, is performed or a plug session is begun.
[0087] Otherwise, if a proximity rating is not supported at 304,
then 312 is executed.
[0088] If a proximity rating is not detected at 306, then at 314,
it is determined if a proximity rating is required. If so, then a
fault state is entered at 316. Otherwise, 312 is executed.
Example 18
[0089] FIG. 8 shows the ground fault detection routine 400. For
example and without limitation, this implements the plot 402 of
FIG. 10. The control electronics 68 of FIG. 4A include a ground
fault current monitoring circuit (not shown) and the current
transformer 64. These components have a known sampling rate, the
contactor/relay 44 has a known period of time to open, and the
routine 400 has a known time for processing and sending control
signals.
[0090] After a ground fault is detected at 402, it is determined at
404 if the sensed ground fault current is higher than a maximum
allowed ground fault current. If the ground fault current is larger
than this value (e.g., without limitation, 350 mA), then a fault is
detected at 405 and the fault routine 500 of FIG. 9 is executed.
Ultimately, this will cause the relay 44 to open and cause a
permanent fault at 215 of FIG. 6. For relatively high fault
currents, there is no automatic reset, but there is instead a
lockout fault that requires a plug session reset. Otherwise, if the
maximum allowed ground fault current is not exceeded at 404, then
at 406, the required time to trip based upon the ground fault
current is determined along with the elapsed time. Generally, the
way that variable ground fault tripping works is that if the ground
fault monitoring circuit senses a relatively small current that is
under the current-time plot 402 of FIG. 10, and if there is
sufficient time to take another sample of ground fault current and
still ultimately timely trip, then another sample is taken.
Otherwise, if the current is too high and there is not enough time,
then the ground fault trip is immediate.
[0091] Next, at 408, if there is sufficient time remaining since
the initial measurement to take another measurement and still trip
open the relay 44 if the ground fault current remains constant,
then another measurement is taken at 410. On the other hand, if
there is insufficient time at 408, then a fault is detected at 405
and the fault routine 500 of FIG. 9 is executed.
[0092] After 410, at 412, if the ground fault current read is zero,
then there is no ground fault and normal circuit breaker operation
is resumed at 414. Otherwise, if the current read is nonzero, then
the average current with the elapsed amount of time is used to
calculate the time remaining to trip and step 404 is repeated. The
process continues until the ground fault monitoring circuit causes
a trip after 405, or the ground fault current goes to zero and
normal circuit breaker operation is resumed at 414.
Example 19
[0093] FIG. 9 shows the fault and lockout logic routine 500 of the
control electronics 68 of the circuit breaker 2' of FIG. 4A. First,
at 502, a fault is detected by the top level routine 200 of FIG. 6.
Then, at 504, the fault type is determined. At 506, if the fault
type is permanent 508, then at 510 a permanent fault state 510 is
entered. This state 510 is exited in response to a software reboot
512, which causes a non-fault state 514 to be entered. Otherwise,
if a temporary fault 516 is determined at 506, then at 518, it is
determined if the fault was within an initial plug-in window (e.g.,
without limitation, an initial time period after the load is
plugged in; a configurable amount of time; about one second; any
suitable time). If the fault was not within the initial plug-in
window, then a lockout counter is incremented at 520. Then, at 522,
it is determined if a lockout fault threshold is reached. If so,
then a lockout state is entered at 524. This state is exited by
either a plug session ending or lockout being cleared at 525, after
which the non-fault state 514 is entered. Otherwise, if the lockout
fault threshold is not reached at 522, then an auto-reset timer is
started at 526. This state exists until the auto-reset timer
expires, a user clears a temporary fault, or the end of a plug
session at 527, after which the non-fault state 514 is entered. The
non-fault state 514 exits in response to a fault 528, which causes
the fault detected state to be entered at 502.
Example 20
[0094] As will be discussed, below, in connection with FIGS. 11-13,
a power vending machine (PVM) circuit breaker 600 can bill a user
for energy consumed through the PVM circuit breaker. For example, a
metering function 602 (FIG. 11) uses a logic circuit 604 (FIGS. 11
and 12) to store timestamped energy values 606 in a persistent
database 608 in memory 610. Both of the metering function 602 and
the logic circuit 604 are within the housing of the PVM circuit
breaker 600. The energy values 606, during certain timestamps, can
be "flagged" as belonging to a number of specific users, which
provides energy allocation to each of such number of specific
users. For example, when the electric load 612 (shown in phantom
line drawing), such as the EV 4 (FIG. 4B), is plugged in, the
energy can be suitably allocated (e.g., without limitation, to the
EV's vehicle identification number (VIN) or to an RFID tag swiped
to allow charging, which will allocate the energy to the
corresponding user; to any number of groups associated with the EV
or the user). The circuit breaker 600 also allocates energy to its
specific power circuit (e.g., to electric load 612 (shown in
phantom line drawing in FIG. 11) at terminals 614,616).
[0095] When an electricity source, such as an electric utility 618
(shown in phantom line drawing in FIGS. 11 and 12), which supplies
power to breaker stab 620 (e.g., from a hot line or bus bar (not
shown)) and neutral pigtail 622 (e.g., to a neutral bar (not
shown)) at a panelboard or load center (not shown), is ready to
bill the user, it can do so in a variety of ways through
communication done via an expansion port 624 (FIG. 12), or
optionally through a built-in wireless interface (e.g., without
limitation, Wi-Fi; BlueTooth). One example method is a "meter read"
of the total energy at the time of the reading from a main circuit
breaker (not shown, but which can be substantially the same as or
similar to the circuit breaker 600, except having a relatively
larger value of rated current) of a corresponding panelboard or
load center (not shown). The value of the "meter read" is compared
with the value of the "meter read" from, for example, the previous
month's reading and the difference value is billed.
[0096] Alternatively, the electric utility 618 can download the
database 608 of each circuit breaker, such as 600, in its entirety,
query the energy values 606 as appropriate, and then apply a
suitable rate structure using the timestamps, specific circuits,
and any allocation flags.
[0097] Examples 21-23 (FIGS. 11-13) show the example controllable,
PVM circuit breaker 600, which can include optional support for
communications and/or a number of different add-on modules 626, as
will be discussed.
Example 21
[0098] Referring to FIG. 11, the example PVM circuit breaker 600
can include a number of optional add-on modules 626. An alternating
current (AC) electrical path through the PVM circuit breaker 600
between the electricity source 618 and the load 612 includes a
thermal-magnetic protection function 628, the metering function 602
and controllable separable contacts 630. An AC-DC power supply 632
supplies DC power to, for example, the logic circuit 604 and a
communications circuit 634. Alternatively, the DC power supply 632
can be located outside of the PVM circuit breaker 600 and supply DC
power thereto. The number of optional add-on modules 626 can
provide specific logic and/or I/O functions and a communications
circuit 636. Optional remote software functions 638,640 can
optionally communicate with the communications circuits
634,636.
Example 22
[0099] FIG. 12 shows more details of the example PVM circuit
breaker 600, which includes an external circuit breaker handle 642
that cooperates with the thermal magnetic trip function 628 to
open, close and/or reset corresponding separable contacts 629 (FIG.
13), an OK indicator 644 that is controlled by the logic circuit
604, and a test/reset button 646 that inputs to the logic circuit
604.
[0100] In this example, there is both a hot line and a neutral line
through the PVM circuit breaker 600 along with corresponding
current sensors 648,649, voltage sensors 650,651, and separable
contacts 630A,630B for each line or power conductor. A power
metering circuit 652 of the metering function 602 inputs from the
current sensors 648,649 and the voltage sensors 650,651, and
outputs corresponding power values to the logic circuit 604, which
uses a timer/clock function 654 to provide the corresponding
timestamped energy values 606 in the database 608 of the memory
610. The current sensors 648,649 can be electrically connected in
series with the respective separable contacts 630A,630B, can be
current transformers coupled to the power lines, or can be any
suitable current sensing device. The voltage sensors 650,651 can be
electrically connected to the respective power lines in series with
the respective separable contacts 630A,630B, can be potential
transformers, or can be any suitable voltage sensing device.
Example 23
[0101] FIG. 13 is an example one-line diagram of the example PVM
circuit breaker 600. Although one phase (e.g., hot line and
neutral) is shown, the disclosed concept is applicable to PVM
circuit breakers having any number of phases or poles. A hot line
is received through the termination 620 to a bus bar (not shown).
Electrical current flows through the first circuit breaking element
629 of the thermal-magnetic overload protection function 628 and
flows through a set of controllable separable contacts 630 (only
one set is shown in this example for the hot line) to the load
terminal 614. A first current transformer (CT) 648 provides current
sensing and ground fault detection with customizable trip settings.
The return current path from the load 612 (FIG. 11) is provided
from the load terminal 616 for load neutral back to the neutral
pigtail 622 for electrical connection, for example, to a neutral
bar of a panelboard or load center (not shown). A second CT 649
provides current sensing and ground fault detection with
customizable trip settings. The outputs of the CTs 648,649 are
input by the logic circuit 604, which controls the controllable
separable contacts 630. The power supply 632 receives power from
the hot and neutral lines. The logic circuit communications circuit
634 also outputs to a communication termination point 656 of the
expansion port 624 (FIG. 12).
Example 24
[0102] FIG. 14 shows one example of the number of add-on modules
626 of FIG. 11, which can be an EV add-on module 700. The PVM
circuit breaker 600 of FIGS. 11-13 and the EV add-on module 700 of
FIG. 14 can function in the same or the substantially the same
manner as the circuit breakers 2,2',2'' described herein except
that certain functionality is moved from the circuit breaker 600 to
the module 700. The example module 700 adds a hardware and software
implementation of a suitable EV communications protocol, ground
fault detection at relatively low thresholds, and control of the
controllable separable contacts 630 (FIG. 12). More specifically,
the module 700 performs the functions of SAE J-1772.TM. (for NEMA
markets) or IEC 62196 (where applicable) and provides the pilot
signal 702 (and an optional proximity signal 704) outputs and
inputs in addition to interfacing an external user interface 706.
The module 700 controls the PVM circuit breaker 600 to perform
proper power interlock and conform to the appropriate standards. It
allocates metering information into a plug session history and can
perform analytic functions (e.g., without limitation, use
limitation based on energy; smart scheduling). The module 700
allocates the usage and billing, for example, to a VIN, which can
be used to collect lost tax revenue from fuel purchases, enables
throttling (e.g., controlling the rate of charge), and panel
coordination (e.g., coordination with other controllable PVM
circuit breakers to reduce or manage overall demand usage for the
entire panel or utility service) in order to prevent demand
charges.
[0103] The module 700 includes a first conductor finger 708 for a
first hot line to the PVM circuit breaker 600, and a second
conductor finger 710 for a second hot line or a neutral to such PVM
circuit breaker. The conductor fingers 708,710 are electrically
connected to respective terminals 712,714 for an electric load 715.
These terminals are used to provide AC power into the EV connector
(e.g., 32 of FIG. 4B). For a single-pole EV circuit breaker, these
are a hot line and a neutral. For a two-pole EV circuit breaker,
these are two hot lines. For a three-pole EV circuit breaker, these
are three hot lines.
[0104] A number of current sensors 716 sense a differential current
for a ground fault protection circuit 718, which can output a fault
signal and other current information to a logic circuit 720. The
logic circuit 720, in turn, can communicate externally through a
communication circuit 722 to a first expansion port 724 (e.g.,
without limitation, to provide a trip signal to the PVM circuit
breaker 600) and/or a second expansion port 726 to communicate with
other local or remote devices (not shown). Details of the expansion
ports 724,726 are discussed, below, in connection with FIG. 20.
[0105] The logic circuit 720 also communicates with a memory 728
and the external user interface 706, which can include a number of
indicator lights 730 and a reset button 732. In support of various
EV interface functions, the logic circuit 720 further communicates
with a DC, PWM output and sensor function 734 that interfaces the
pilot signal 702 at terminal 736 and an optional proximity circuit
738 that interfaces the optional proximity signal 704 (or proximity
resistor (not shown)) at terminal 740 for an IEC style EV add-on
module. The module 700 also includes a ground pigtail 742 that
provides a ground to a ground terminal 744.
[0106] The example module 700 can be employed with the PVM circuit
breaker 600 or any suitable circuit breaker disclosed herein that
feeds a suitable electric load. Example protective functions
performed by such circuit breakers can include overcurrent, ground
fault, overvoltage, load interlock and/or a safe automatic reset.
Example control functions include interfaces to the module 700, a
suitable algorithm for the load (e.g., EV) and state management for
the load (e.g., EV).
[0107] Example authentication functions performed by the module 700
include verification of permission to access power or control of
the circuit breaker (i.e., vending power to a load), either locally
or remotely, and additional logic and interlock settings. As an
example, these include determining whether you are allowed to use
power for the load (e.g., to charge an EV), or determining if you
are an administrator allowed to control the circuit breakers.
[0108] Example allocation functions performed by the PVM circuit
breaker 600 include tracking energy usage by department, circuit or
user, limiting the amount of energy usage, and utility grade energy
metering (e.g., 0.2% accuracy of metering).
[0109] Example optional and additional protection and control
functions that can be enabled in the PVM circuit breaker 600 by the
module 700 include interchangeable communication interfaces, remote
control and additional trip curves.
Example 25
[0110] FIG. 15 shows a solar or photovoltaic (PV) add-on module 800
for a plug and play solar system (not shown), including needed
functionality for a "PV-ready electrical circuit". The solar or PV
add-on module 800 provides auto-commissioning and permitting for
solar generation with self-diagnostics. The module 800 is somewhat
similar to the module 700 of FIG. 14, except that the current
sensor 716, ground fault protection circuit 718, reset button 732
and other EV-related components are eliminated. In this example,
the terminals 712,714 are for electrical connection to an inverter
806, and the communication circuit 722' also interfaces to an
inverter communication port 802 for communication with the inverter
806 and a utility communication port 804 for communication with an
electric utility (e.g., electricity source 618 of FIG. 11).
[0111] The disclosed circuit breakers 2,2',2'' and module 800 can
provide a DC string protector (e.g., an electronic circuit breaker
with improved DC overcurrent/reverse current protection, ground
fault detection, and arc fault circuit interruption) and a PV
module shutdown switches monitoring system, which monitors PV
string current and voltage, along with a relatively small window
I-V curve around maximum power for maximum power point
tracking.
[0112] For a solar generation system (not shown), the disclosed
module 800 enables a simple installation, with automatic electrical
permitting and inspection to replace the need for electrical
permits and inspections. A single electrical listing of the entire
plug and play PV system is used to allow a standard PV plug to
connect the PV inverter 806 to the add-on module 800 without
additional permits or inspections, and with automatic structural
permitting and inspection. The add-on module 800 includes a
suitable communication interface, such as the inverter
communication port 802, to notify the authority having jurisdiction
(AHJ) of the solar installation and automatically commission and
permit the installation without having an inspector visit the site
to the extent possible. The add-on module 800 further includes a
suitable communication interface, such as the utility communication
port 804, to permit automatic grid interconnection by notifying the
utility of the solar installation and automatically provisioning
the installation to backfeed into the grid.
[0113] Other optional features of the add-on module 800 can
include: (1) grid support communication functions (e.g., without
limitation, status check/self diagnostics, which check the status
of individual components of the inverter 806 and the corresponding
PV modules (not shown) using artificial neural network based
pattern recognition techniques; (2) self
configuration/self-healing, in order that when there is a problem
with components, the circuit breaker can still operate to provide
power to the grid safely until the system is fixed (e.g., a limp
home capability); (3) performance monitoring and lifetime
estimation for performance monitoring of components for
degradation, including notification for preemptive replacement; (4)
volt/var support by the use of intelligent/smart/connected
inverters (via the add-on module 800) to perform grid stability
functions (this allows inverters to improve grid voltage or power
factor); (5) utility power demand/frequency control (e.g., the
utility might not want the PV inverter 806 connected or might need
relatively lower power); (6) load as a resource by leveraging other
loads in a PV module panel (not shown); and (7) GridEye.TM. or
other suitable power quality monitors or sensors, which send the
utility, frequency, voltage, and phase angle information as well as
PV inverter power quality information. GridEye.TM. covers a
wide-area grid monitoring network for the three North American
power grids. This provides additional monitoring points at planned
renewable generation sites--such as wind farms--to characterize the
system's dynamic behavior before and after the installation of
renewable sources. This produces dynamic system behavior data for
insight into how renewable generation assets change the dynamic
behavior of the electric grid. These data can also be used to
estimate dynamic modeling parameters for planning and operation
[0114] If used in a PV module panel (not shown), a different add-on
module 800 can alternatively perform automatic transfer switch
(ATS) functionality with utility islanding. For example, a software
interlock of a main circuit breaker (not shown) and the generation
system (not shown) would allow backfeeding if the utility power is
present. Otherwise, when loss of utility power is detected, the
add-on module 800 will: (1) command opening the main circuit
breaker (not shown); (2) command closing the generation/energy
storage circuit (not shown); and (3) send a signal to start the
supply of power to the on premise generation source to able to
supply power, such as a diesel generator. The load circuits are
allowed to run in island mode in the premise. This safely
electrically islands the premise to protect workers on the utility
line while retaining power at the PV module equipped site. This ATS
and islanding functionality could be a different add-on module 800
(for other energy sources that are not solar), but without
PV-specific features.
Example 26
[0115] Further to Example 25, the example add-on module 800 enables
relatively quick and easy installation of PV components, in order
that the entire process may be conducted safely without the need of
professional electrical services or on-site permitting.
Pre-installed infrastructure (e.g., meters; load centers; circuit
breakers; communication gateways) are enabled to support the future
installation of PV components. After purchase, this PV equipment
seamlessly connects to the existing infrastructure without the need
for inspection. Pre-installation can be made for the anticipation
to install any new smart grid-enabled equipment, including PV, as
well as electric vehicle supply equipment (EVSE), local energy
storage, smart water heaters, or other devices that can be
justified on a broader smart-grid basis. This pre-installation
approach can potentially be correlated with smart meter rollouts
and utility-driven home energy management programs for retrofit
upgrades or implanted into requirements for new construction.
Furthermore, in order to accomplish these tasks, both internal
connectivity and external connectivity to utility companies and
AHJ's is critical to ensure safe installation, continued
operations, and maintenance.
Example 27
[0116] FIG. 16 shows an HVAC add-on module 900. The module 900 is
somewhat similar to the module 700 of FIG. 14, except that the
current sensor 716, ground fault protection circuit 718, reset
button 732 and other EV-related components are eliminated. In this
example, the terminals 712,714 are for electrical connection to
HVAC equipment 916, and the communication circuit 722'' also
interfaces to a wireless communication circuit 902. In place of the
EV-related components, various HVAC-related components are added
including a thermostat 904, a plurality of solid state relays 906
that output to a plurality of example push terminals 908 for HVAC
signals such as: R.sub.H, W.sub.1, Y.sub.1, Y.sub.2, G, C, * (e.g.,
W.sub.3 (third stage heating), E, HUM (humidify), DEHUM
(dehumidify)), OB (orange or blue; orange is the reversing valve,
energize to cool (changes from heat to cool on heat pumps); blue is
sometimes the common side of a transformer (needed on some
electronic thermostats or if there are indicator lamps), or a
reversing value (energize to heat as orange), or some vendors
sometimes use (B) as common), R.sub.c and AUX/W.sub.2, as shown in
Table 4A (legacy systems) and Table 4B (heat pumps and staged
systems), respectively, as wells as damper terminals 910,912. The
logic circuit 720 interfaces to a number of user interface buttons
914 and cooperates with the communication circuit 722'', the
thermostat 904 and the solid state relays 906 to control and
monitor the HVAC equipment 916.
[0117] The example module 900 can replace a conventional thermostat
and place all HVAC wiring in a load center (not shown). For a
commercial building (not shown), this can include control (e.g.,
without limitation, of actuators; dampers). A number of
communicating temperature sensors (not shown) can be located
throughout the building to provide temperature input (e.g., through
the expansion or wireless communication ports 726,902) to the HVAC
add-on module 900 and can also be used to adjust temperature
settings. The module 900 can also perform actions to save energy
(e.g., without limitation, cycling a compressor; setting heating
and cooling schedules).
TABLE-US-00004 TABLE 4A Probable Terminal Wire Color Signal
Description C Black 24 Vac From one side of the common 24 Vac
transformer (24 Vac neutral) R or V Red 24 Vac power From other
side of to be switched the 24 Vac transformer (24 Vac L1) R.sub.H
or 4 Red 24 Vac heat call Same as R, but switch power dedicated to
the heat call switch R.sub.c Red 24 Vac cooling Same as R, but call
switch dedicated to the power cooling call switch G Green Fan Fan
switch on thermostat-connected to R when fan/auto switch is in the
fan position W or W.sub.1 White Heating call Connected to R or
R.sub.H when thermostat calls for heat (can be jumpered to Y on a
heat pump; on others can be second stage heating) Y or Y.sub.1
Yellow Cooling call Connected to R or R.sub.c when thermostat calls
for cooling; also cooling or first stage heating on a heat pump;
most often connected to G when fan switch is set to auto
TABLE-US-00005 TABLE 4B Probable Terminal Wire Color Signal
Description Y.sub.2 Blue or Second stage Orange cooling W.sub.2 or
Varies Second stage First stage auxiliary AUX heating heating on a
heat pump E Varies, Emergency heat Disable the heat blue, pink,
relay on a heat pump and turn on gray, tan pump; active all first
stage Aux the time when heating selected, usually not used O
Varies, Reversing valve Energize to cool orange (changes from heat
to cool on heat pumps) B Varies, Sometimes Can be heating blue,
black, common side of changeover or brown, transformer; common of
orange needed on some transformer electronic thermostats or if you
have indicator lamps or reversing valve (energize to heat); some
vendors sometimes use (B) as common X Varies Can be common or
sometimes emergency heat relay X.sub.2 Varies Second stage Can be
emergency heating or heat relay indicator lights on some
thermostats T Varies, tan Outdoor Used on some or gray anticipator
reset products L Varies Service light
Example 28
[0118] FIG. 17 shows a general purpose I/O add-on module 1000. The
module 1000 is somewhat similar to the module 900 of FIG. 16,
except that the HVAC-related components and wireless communication
circuit 902 are eliminated. In this example, the terminals 712,714
are for electrical connection to any suitable load (not shown), and
the logic circuit 720 interfaces a processor I/O expander circuit
1002 that inputs from and/or outputs to a plurality of example push
terminals 1004.
[0119] The module 1000 can provide analog inputs (e.g., for control
signals), analog outputs, digital outputs (e.g., for external
systems; relays; control signals) or digital inputs (e.g., for
digital switches). The analog or digital inputs can be communicated
through the example circuit breakers, such as 2,2',2'',600,
disclosed herein and can provide program control of such circuit
breakers (e.g., without limitation, solar harvesting; digital
switches; shunt trip; relay commands).
[0120] Further to Example 1, the add-on module 1000 can perform
Boolean algebra and basic if-then-else functions with the logic
circuit 720 using its inputs and outputs, and/or can be used as a
binary status indicator (e.g., without limitation, to indicate that
a main circuit breaker is open or closed) with the indicator lights
730.
[0121] The add-on module 1000 can employ the set of controllable,
general purpose I/O terminals 1004 whose capabilities may include,
for example and without limitation, direction (e.g., the terminals
can be configured to be input or output using an enable mask);
enabled/disabled; input values are readable (e.g., without
limitation, high=1, low=0); output values are writable/readable;
and input values can be used as interrupt request lines (e.g.,
without limitation, for wakeup events).
[0122] The add-on module 1000 can employ direct memory access (DMA)
to efficiently move relatively large quantities of data into or out
of the module, or provide support for "bitbanging", which can
provide software emulation of a hardware protocol.
[0123] The example general purpose I/O add-on module 1000 can
enable generic serial communication with a load (not shown). By
providing a corresponding device, such as the example circuit
breakers, with embedded intelligence and communication, this can
provide an interface that connects that device to the "smart grid".
Non-limiting examples of such communication include sending utility
billing rates and time-of-use rate structures from the utility back
office, through this add-on module 1000 and down to the load (e.g.,
without limitation, a washer; dryer; dishwasher), in order that the
device can decide when the optimum time is to perform their
function (e.g., to turn themselves on when energy is cheapest).
[0124] Examples 29 and 30 (FIGS. 18A-18C and 19) show various
non-limiting example embodiments for coupling add-on modules to
circuit breakers.
Example 29
[0125] FIG. 18A shows a two-pole add-on module 1100 coupled to one
end of a two-pole circuit breaker 1102.
[0126] FIG. 18B shows a two-pole add-on module 1104 coupled to one
side of a two-pole circuit breaker 1106 with jumpers 1108
therebetween.
[0127] FIG. 18C shows a relatively small snap-on two-pole add-on
module 1110 coupled to one end of a two-pole main circuit breaker
1112 or optionally to a separate local controller (not shown),
which can optionally serve as an aggregator for other circuit
breakers 1114,1116.
Example 30
[0128] FIG. 19 shows a PVM system 1200 including a main circuit
breaker 1202, which functions as or in conjunction with a local
controller and/or gateway (not shown), and a plurality of PVM
circuit breakers 1204. Six of eight of the example PVM circuit
breakers 1204 include add-on modules 1206, and one of those six PVM
circuit breakers 1206 includes a further "stacked" add-on module
1208. The "stacked" add-on module 1208 permits combining features
of multiple add-on modules with different functionality onto the
same circuit breaker, such as 1204, and its corresponding power
circuit (not shown). For instance, an EV add-on module 1206
combined with an RFID authentication add-on module 1208
authenticates a user operatively associated with the EV to be
charged before every charge session. For example, communication
between the main circuit breaker 1202 and the PVM circuit breakers
1204 is through two of the PVM circuit breakers 1204, through five
of the add-on modules 1206, and through the "stacked" add-on module
1208.
[0129] For example, multiple circuit breakers 1204 and/or add-on
modules 1206,1208 are daisy-chained through expansion ports (e.g.,
624 of FIG. 12, 726 of FIG. 14) to a controller 1202 for a panel or
enclosure (not shown), such that the controller acts as a gateway,
central repository for data, proxy device for a larger network,
and/or a local stand-alone controller. Each device's expansion port
can be coupled together in a daisy-chained fashion onto a common
serial bus using a suitable communication protocol (e.g., without
limitation, Modbus.RTM. over RS-485; Eaton.RTM. SMARTWIRE-DT.TM.).
One device can act as a "master" while all other devices are
individually addressable slaves. The master device can have its own
controller logic and/or an additional communication interface to
act as a gateway onto another communication protocol.
Example 31
[0130] FIG. 20 shows an example of expansion port electrical
connections 1300, which electrically connect a circuit breaker 1302
to an add-on module 1304 using a suitable serial interface 1306.
The electrical connections 1300 include expansion port pins 1308 at
one end of the circuit breaker 1302, expansion port receptacles
1310 at one end of the add-on module 1304, and expansion port pins
1312 at the opposite end of the add-on module 1304. The disclosed
expansion port includes eight example conductors: signal ground
1314, neutral 1316, COMM+ 1318, CONTROL PWR+ 1320, status 1322,
contact control 1324, COMM- 1326, and CONTROL PWR- 1328. Status
1322 and contact control 1324 respectively report the status of and
control the separable contacts (not shown, but see the controllable
contacts 630 of PVM circuit breaker 600 of FIG. 11) of the circuit
breaker 1302.
[0131] These signals 1322,1324 are referenced to signal ground
1314. COMM+ 1318 and COMM- 1326 either provide communications
between the circuit breaker 1302 and the add-on module 1304, or
route the COMM+ 1318 and COMM- 1326 signals of the circuit breaker
1302 through the add-on module 1304. CONTROL PWR+ 1320 and CONTROL
PWR- 1328 provide power from the circuit breaker 1302 to the add-on
module 1304.
[0132] The example serial port provided by COMM+ 1318 and COMM-
1326 exchanges on/off control, provides an interface for external
and/or remote communication, reports status information (e.g.,
without limitation, on/off/tripped; fault reason; fault time; time
until reset; number of operations; serial number; clock; firmware
version; time/clock), and reports metering values (e.g., without
limitation, time-stamped values; voltage; current; power consumed
by the load; power generated and fed into the panel). The
time-stamped values can include net energy (watt-hours) (e.g.,
broken down by real, active, and reactive types, where each type
contains forward, reverse, net, and total); and peak demand (watts)
(e.g., calculated within a configurable time window size and reset
at configurable time intervals). The example serial port includes a
suitable serial bus in order to pass communications between
multiple circuit breakers and add-on modules as was discussed above
in connection with FIG. 19.
[0133] The expansion port controls the controllable separable
contacts 630 of the PVM circuit breaker 600 (FIG. 12), reports the
state of such separable contacts, and can be used to provide power
to the embedded electronics from an external power source.
[0134] The power prongs or stabs (e.g., 708,710 of FIG. 14) fit
into the termination points (e.g., 614,616 of FIG. 12) of the
circuit breaker 1302 in order to provide power signals to the
add-on module 1304. The add-on module 1304 has corresponding
termination points 712,714 (FIG. 14) on the other side for the
electric load (not shown) or for additional "stacked" add-on
modules (e.g., 1208 of FIG. 19) that may be added.
[0135] The add-on module expansion port receptacles 1310 have the
same communication format as the expansion port pins 1312, but are
the opposite gender for mating with the circuit breaker expansion
port pins 1308.
Example 32
[0136] FIGS. 21 and 22 (Examples 33 and 34, respectively) show
circuit breakers 1400 and 1450, respectively, which are similar to
the PVM circuit breaker 600 of FIGS. 11-13. The main difference is
that these circuit breakers 1400 and 1450 include a single set of
separable contacts 1406A,1406B or 1452,1454 per conductor (e.g.,
without limitation, hot line; neutral). The separable contacts 1406
are controlled for the purpose of on/off control and optionally for
ground fault protection using the add-on module 700 of FIG. 14 or
the logic circuit 604. However, thermal-magnetic protection through
another set of separable contacts is not provided.
[0137] In contrast to Example 3, the thermal-magnetic protection
is, instead, implemented, for example and without limitation, in
control electronics firmware of the logic circuit 604, somewhat
similar to how the ground fault protection is provided thereby.
[0138] For example, the single sets of separable contacts
1406A,1406B can each be solid-state, with all protective and
electric load (e.g., EV) functions being provided by a single
electronic switching device.
[0139] The disclosed relay 44 of FIG. 4A is preferably small enough
to fit inside the circuit breakers 1400,1450 and handle switching
under load for current values under normal conditions (e.g., rated
current). The relay 44, however, is not capable of opening, without
damage, under fault conditions of ten times rated current. Hence,
in that example, the example thermal-magnetic protection is
employed in series with the second set of controllable separable
contacts 24' of FIG. 4A.
[0140] Although separable contacts 24',1406A,1406B are disclosed,
suitable solid state separable contacts can be employed. For
example, the disclosed circuit breaker 2 includes a suitable
circuit interrupter mechanism, such as the separable contacts 24'
that are opened and closed by the operating mechanism of the relay
44, although the disclosed concept is applicable to a wide range of
circuit interruption mechanisms (e.g., without limitation, solid
state switches like FET or IGBT devices; contactor contacts) and/or
solid state based control/protection devices (e.g., without
limitation, drives; soft-starters; DC/DC converters) and/or
operating mechanisms (e.g., without limitation, electrical,
electro-mechanical, or mechanical mechanisms).
Example 33
[0141] In the PVM circuit breaker 1400 of FIG. 21, the circuit
breaker handle 642 and the thermal-magnetic protection function 628
of FIG. 12 are replaced by an on/off button 1402 and a fuse 1404.
Here, the separable contacts 1406 can be, for example and without
limitation, the relay separable contacts 24' of FIG. 4A or,
preferably, a suitable solid state switching device, which can
handle switching under both normal and fault conditions.
[0142] In this example, the thermal-magnetic protection separable
contacts (first circuit breaking element) 629 of FIG. 13 are
eliminated. This allows for automatic-reset and remote control,
even if an overcurrent or short circuit condition causes the fault.
Additional short circuit protection is provided by the fuse 1404,
which is electrically connected in series with the separable
contacts 1406A in the hot line. Instead of the circuit breaker
handle 642, the on/off button 1402 is input by the logic circuit
604, which controls the on or off state of the single sets of
separable contacts 1406A,1406B for each of the hot line and the
neutral line, respectively.
[0143] If a resettable fuse 1404 is employed, then it would
automatically reset after a fault was cleared. Otherwise, the fuse
1404 would blow and, therefore, need replacement after a fault
current. The single set of separable contacts 1406 can be used at
all other times.
[0144] Alternatively, software of the logic circuit 604 can emulate
the fuse 1404 and trip the relay 44 (not shown, but see FIG. 4A)
right before the fuse 1404 blows, if the fault can be detected fast
enough.
Example 34
[0145] The circuit breaker 1450 of FIG. 22 is similar to the
circuit breaker 1400 of FIG. 21, except that the fuse 1404 is not
employed. Also, in this example, each of the sets of the separable
contacts 1452,1454 is a suitable solid state switching device,
which can handle switching under both normal and fault
conditions.
Example 35
[0146] Since PVM circuit breakers, such as for example
600,1400,1450, can include a wide range of features, various
different add-on modules can be employed. For example, the EV
add-on module 700 (FIG. 14) is coupled to the PVM circuit breaker
600 (FIGS. 11-13) with ground fault protection.
[0147] Examples 36-62 discuss a variety of different add-on
modules, such as 626 of FIG. 11.
Example 36
[0148] An authentication add-on module performs user authentication
using, for example and without limitation, RFID or the Internet.
This can allocate usage of power into, for example, groups, power
circuits, and users.
Example 37
[0149] A tenant billing software add-on module reads metering
information from the PVM circuit breaker expansion port 624 and
performs tenant metering/billing for a property owner. This
function can be combined with the authentication add-on module
(Example 36) (e.g., as shown with the add-on module 1206 and the
"stacked" add-on module 1208 of FIG. 19) to charge individual users
instead of individual branch circuits.
Example 38
[0150] A communications/protocol add-on module enables the PVM
circuit breaker 600 to communicate using different protocols or
languages to the electric utility, customer or end devices. This
can include controlling the PVM circuit breaker 600 or displaying
usage information, for example and without limitation, on a local
webpage, through a cloud service, or on a suitable smart phone.
Non-limiting communication examples include: Wi-Fi; cellular;
Ethernet; serial; Smart Energy.RTM.; OpenADR.TM.; BacNET.TM.;
Modbus.RTM.; power line carrier (PLC); SmartWire DT; IEC 61850; and
DNP3.
Example 39
[0151] A schedule add-on module performs scheduling to turn on/off
electric loads. This can be employed, for example and without
limitation, to control exterior lighting with sunset/sunrise, cycle
a pool pump to reduce energy usage, and have different and
programmable holiday schedules.
Example 40
[0152] An analog/digital input add-on module allows analog or
digital inputs to be communicated through PVM circuit breakers,
such as 600, and program control thereof (e.g., without limitation,
solar harvesting; digital switches; shunt trip).
Example 41
[0153] A programmable logic controller (PLC) add-on module
implements PLC ladder logic for control and/or monitoring.
Example 42
[0154] A proprietary main circuit breaker add-on module provides
all of the functionality of a corresponding proprietary main
circuit breaker inside of the add-on module.
Example 43
[0155] A group control add-on module allows programming to control
groups of circuit breakers instead of just one circuit breaker.
Example 44
[0156] A lighting add-on module provides scheduling and dimming
functions. This can also provide alerts when the lights go out by
detecting a corresponding drop in current.
Example 45
[0157] A power signature add-on module performs analysis of the
voltage/current (V-I) curves for a known, dedicated load type and
determines, notifies and/or trips for any failures that occur.
Example 46
[0158] A load ID add-on module identifies a specific load (e.g.,
down to the serial number) or load category (e.g., in terms of
current rating or device type) when it is electrically connected.
This module can employ, for example and without limitation,
NFC/RFID (Near Field Communications/RFID) or power line carrier for
identification purposes).
Example 47
[0159] A load annunciation and power interlock add-on module
provides EV interfaces for EV applications.
Example 48
[0160] A surge protection add-on module provides surge protection
for an individual circuit breaker, for a main circuit breaker, or
for an entire circuit breaker panel.
Example 49
[0161] A battery management system add-on module controls an
external inverter to properly charge batteries.
Example 50
[0162] A DC inverter/DC distribution system add-on module places an
inverter and DC distribution system inside the circuit breaker
panel to provide DC power from the load center. This could be used
to charge electronics and power other DC devices.
Example 51
[0163] A data storage add-on module increases the storage capacity
for a PVM circuit breaker. This can be employed, for example and
without limitation, to store relatively larger amounts of metering
data, keep a plug session history for the EV add-on module, or
store relatively larger amounts of allocation to specific
users.
Example 52
[0164] A power manager--load coordinator add-on module commands
loads to operate in a coordinated fashion to minimize power/energy
demand and ultimately cost based on time-of-use or real-time
prices.
Example 53
[0165] A ground fault add-on module provides ground fault
protection with adjustable ground fault current thresholds.
Example 54
[0166] An arc fault add-on module provides arc fault
protection.
Example 55
[0167] A building automation controller add-on module permits a
load center to perform building automation connectivity, management
and programming.
Example 56
[0168] An HVAC controller add-on module controls and cycles a
compressor (e.g., turns off the compressor, but leave the fan
running), provides augmented learning techniques, and saves energy.
For commercial buildings, it controls devices, such as actuators
and dampers.
Example 57
[0169] A remote control add-on module controls a power circuit with
a switch or a smart phone application. A simple variant is a dry
contact to control the circuit breaker. A more advanced version is
securely connected to the cloud to be controlled from any remote
location.
Example 58
[0170] An advanced metering add-on module provides advanced
metering functions (e.g., without limitation, harmonics; sags;
swells; power factor; waveform capture for faults).
Example 59
[0171] An energy efficiency and analysis add-on module provides
recommendations for how to save energy. This can include, for
example and without limitation, reports on usage (e.g., down to
branch circuits) combined with weather, solar output, and which
circuits have phantom loads that could be turned off.
Example 60
[0172] A meter verification add-on module verifies an individual
meter by taking a circuit breaker out of service, running known
amounts of energy through the circuit breaker, and comparing the
meter output. This can be performed on a schedule or on demand with
the results reported back to the electric utility or other
facility.
Example 61
[0173] An islanding main circuit breaker add-on module trips the
main circuit breaker when power is lost from the electric utility
(and closes it when it is reestablished) in order to safely allow a
home with power generation capability to have electric power in a
utility islanded mode. Otherwise, a serious safety issue can occur
which could kill or seriously injure an outside utility worker by
having electric power appear upstream where it normally should not
be (e.g., during maintenance activities).
Example 62
[0174] A circuit breaker add-on module can provide circuit breaker
control and monitoring through the circuit breaker expansion port
624 (FIG. 12). Also, additional logic can check the status (e.g.,
open; closed; tripped; indication of trip type, if available) of
the circuit breaker and can override the controllable separable
contacts 630. In some embodiments, the controllable separable
contacts 630 can be externally controlled by the add-on module,
which can: (1) vary trip curves; (2) vary interlock
mechanisms/logic stored and commanded by the logic circuit 604; (3)
vary protective functions and identify current and voltage
signatures; (4) determine the "wellness" of the downstream electric
load device; (5) report load health information through a
communications port (e.g., 726 of FIG. 14); and (6) open the
controllable separable contacts 630 (FIG. 12) if the health reaches
an unsatisfactory level.
[0175] While specific embodiments of the disclosed concept have
been described in detail, it will be appreciated by those skilled
in the art that various modifications and alternatives to those
details could be developed in light of the overall teachings of the
disclosure. Accordingly, the particular arrangements disclosed are
meant to be illustrative only and not limiting as to the scope of
the disclosed concept which is to be given the full breadth of the
claims appended and any and all equivalents thereof.
* * * * *