U.S. patent number 3,812,400 [Application Number 05/338,405] was granted by the patent office on 1974-05-21 for modular ground fault interrupter.
This patent grant is currently assigned to Harvey Hubbell Incorporated, I-T-E Imperial Corporation. Invention is credited to Carl E. Gryctko, Frank C. Jaconette, Paul Muchnick.
United States Patent |
3,812,400 |
Gryctko , et al. |
May 21, 1974 |
MODULAR GROUND FAULT INTERRUPTER
Abstract
A circuit breaker module and a sensor module are secured
together side by side to form a ground fault interrupter, with all
moving parts of the interrupter being contained within the housing
of the circuit breaker module. The modules are electrically
connected at an interface region disposed outside of the module
housings. This interface region is enclosed by a cover that
cooperates with portions of the sensor module housing to form a
plurality of compartments each of which contains a different
electrical splicing element.
Inventors: |
Gryctko; Carl E. (Haddon
Heights, NJ), Muchnick; Paul (Norwald, CT), Jaconette;
Frank C. (Trumbell, CT) |
Assignee: |
I-T-E Imperial Corporation
(Spring House, PA)
Harvey Hubbell Incorporated (Bridgeport, CT)
|
Family
ID: |
23324697 |
Appl.
No.: |
05/338,405 |
Filed: |
March 5, 1973 |
Current U.S.
Class: |
361/45; 335/18;
200/5B; 361/115 |
Current CPC
Class: |
H01H
71/0271 (20130101); H01H 2071/0278 (20130101) |
Current International
Class: |
H01H
71/02 (20060101); H02h 001/02 () |
Field of
Search: |
;317/18D,18R,17,38,58,112,118,119,120 ;335/18,20,6 ;200/5B |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Miller; J. D.
Assistant Examiner: Salce; Patrick R.
Attorney, Agent or Firm: Ostrolenk, Faber, Gerb &
Soffen
Claims
The embodiments of the invention in which an exclusive priviledge
or
1. An interrupter assembly including a switch module and a sensor
module secured together side by side; said switch module including
a relatively narrow first housing having a first side adjacent said
sensor module, line and load terminals at the front and rear,
respectively, of said first housing, cooperating contacts, a
contact operating means for opening said contacts, and a shunt trip
device which upon actuation thereof operates said mechanism to open
said contacts; said sensor module including a fault detector, first
means for generating a shunt grip actuating signal when a fault of
predetermined magnitude is sensed by said detector, and a
relatively narrow second housing wherein said fault detector and
first means are disposed, said second housing having a second side
adjacent said first side; a first plurality of electrical leads
extending external of said first housing from at least said shunt
trip device through first aperture means in said first side; a
second plurality of electrical leads extending external of said
second housing from at least said first means and said detector
through second aperture means in said second side; a plurality of
splice means electrically connecting said first plurality of leads
to said second plurality of leads to electrically connect said
first means to said shunt trip and electrically connect a portion
of said detector in a series circuit extending between said
terminals and including said contacts; said splice means being
disposed at a region to the rear of said first housing; and cover
means at said region cooperating with portions of said second
housing to form an enclosure wherein said
2. An interrupter assembly as set forth in claim 1 in which the
second aperture means is positioned to the rear of said first
housing and is
3. An interrupter assembly as set forth in claim 2 in which the
plurality of splice means is positioned to the rear of said second
aperture means.
4. An interrupter assembly as set forth in claim 2 in which there
is a plurality of channels formed through the cooperation of said
first and second sides; the leads of said first plurality of leads
being disposed within said channels; said channels extending from
said first aperture
5. An interrupter assembly as set forth in claim 4 in which there
is a barrer on said channel wall having guide notches aligned with
said channels for positioning said first plurality of leads as they
enter said
6. An interrupter assembly as set forth in claim 4 in which there
are a plurality of generally parallel barriers within said cover
positioned
7. An interrupter assembly as set forth in claim 6 in which said
barriers
8. An interrupter assembly as set forth in claim 7 in which there
is another barrier transverse to said parallel barriers; said
another barrier having guide notches aligned with said channels for
positioning said first plurality of leads as they extend into said
region in the spaces between
9. An interrupter assembly as set forth in claim 8 in which each of
the channels is formed by aligned cooperating grooves in said first
and second
10. An interrupter assembly as set forth in claim 1 in which the
housings are substantially of equal width and the forward surfaces
thereof are generally aligned; similarly positioned slot in each of
said housings at the front ends thereof; said slots being spaced
apart by the width of one of said housings and each being
constructed to receive a plug-in connector of a panelboard; said
line terminal being aligned with the slot of said first housing to
engage a panelboard plug-in connector inserted into the slot of
said first housing; first and second flexible leads, extending from
a portion of said detector through aperture means at the rear end
of said second housing, for connection to a neutral terminal of a
panelboard and an electrical load respectively.
Description
Conventional circuit breakers for home and light industrial
applications usually have thermal and magnetic fault responsive
trip means to automatically open the main contacts of the circuit
breaker when excessively high current flows through the main
contacts. The protection afforded prevents damage to load wiring
and to the load. However, this does not insure that low magnitude
fault currents caused by high resistance faults to ground will not
start fires or result in injury to personnel.
In order to obtain protection against the aforesaid low magnitude
faults, so-called ground fault interrupters have been provided to
extend the protection afforded by conventional circuit breakers.
Typical circuitry for a ground fault interrupter is described in
U.S. Pat. No. 3,555,359, issued Jan. 12, 1971, to A. R. Morris for
a "Circuit Protective Device."
In accordance with the instant invention, circuit breaker and
ground fault sensor modules of substantially the same relatively
narrow width, say one inch, are secured together in side-by-side
relationship to form a ground fault interrupter that is mountable
in many existing panelboards. The circuit breaker module housing
contains all of the mechanical moving elements of the interrupter
including a shunt trip device that is actuated in accordance with
signals generated by these sensor unit responsive to the sensing of
predetermined ground fault currents. The sensor module includes a
differential transformer having a primary winding electrically
connected to the main contacts of the circuit breaker module in a
series circuit extending between the line and load terminals of the
circuit breaker module. A solid-state switch of the sensor module
is electrically connected to the shunt trip device to control
energization thereof. Electrical connections between the modules
are made at an inter-face region at the load end of the circuit
breaker module. This interface region is enclosed by a cover and is
divided into compartments whereby the individual electrical
splicers are isolated from each other.
As will hereinafter be seen, the construction in accordance with
the instant invention is such that the modules may be manufactured
and stored at different locations, and assembly of a circuit
breaker module with a sensor module is readily accomplished, even
at another location. Assembly is facilitated by providing channels
and notches to position the electrical leads extending from the
circuit breaker module and to direct these leads into predetermined
compartments of the interface region.
Accordingly, a primary object of the instant invention is to
provide a novel construction for a ground fault interrupter
constructed of a circuit breaker module and a sensor module.
Another object is to provide an interrupter of this type in which
all of the mechanical moving parts are contained within the housing
of the circuit breaker module.
Still another object is to provide an interrupter of this type
having a novel interface region where the electrical connections
between the modules are made.
These objects as well as other objects of this invention will
become readily apparent after reading the following description of
the accompanying drawings in which:
FIG. 1 is a perspective looking toward the load end of a ground
fault interrupter constructed in accordance with teachings of the
instant invention.
FIG. 2 is a side elevation of the interrupter looking in the
direction of arrows 2--2 of FIG. 1, with the cover of the interface
region removed.
FIG. 3 is a plan view looking in the direction of arrows 3--3 of
FIG. 2 with the cover of the interface region exploded from the
remainder of the interrupter.
FIGS. 4 and 5 are respective load and line end views of the
interrupter, looking in the direction of the respective arrows 4--4
and 5--5 of FIG. 2.
FIG. 6 is a side elevation of the sensor module housing looking in
the direction of arrows 6-6 of FIG. 3.
FIGS. 7 and 8 are fragmentary cross-sections taken through the
respective lines 7--7 and 8--8 of FIG. 6, looking in the direction
of the respective arrows 7--7 and 8--8.
FIG. 9 is a side elevation of the circuit breaker module housing
looking in the direction of arrows 9--9 of FIG. 3.
FIG. 10 is a cross-section taken through line 10--10 of FIG. 9,
looking in the direction of arrows 10--10.
FIG. 11 is an elevation looking in the direction of arrows 11--11
of FIG. 3, showing the inside of the interface region cover.
FIG. 12 is an end view of the cover looking in the direction of
arrows 12--12 of FIG. 11.
FIG. 13 is primarily an electrical schematic showing the ground
fault interrupter of FIG. 1 connecting an electrical load to an
A.C. power source.
Now referring to the figures. Ground fault interrupter 15 is
constructed of circuit breaker module 16 and ground fault sensor
module 17 secured together in abutting side-by-side relationship by
rivets 18, 19. Circuit breaker module 16 is a one-inch wide
molded-case circuit breaker of the type described in U.S. Pat. No.
3,703,691 issued November 21, 1972, to C. E. Gryctko et al. for a
SHUNT TRIP WITH LOAD TERMINAL, modified to conform with the
electrical arrangement illustrated in the schematic of FIG. 13
hereof.
As seen in FIG. 13, the current path through circuit breaker module
16, between line 21 and load 22 terminals thereof, consists of
female-type plug-in terminal 21 to stationary contact 23 engaged by
movable contact 24 on contact arm 25, through contact arm 25, to
and through thermal trip bimetal 26 and magnetic trip coil 27 to a
gap between coil 27 and load terminal 22, which gap is bridged by
primary winding 28 of balanced transformer 30 that is part of
sensor module 17.
The other primary winding 29 of transformer 30 is connected by lead
32 to the grounded terminal of a.c. power source 33 and is
connected by lead 34 to one terminal of electrical load 35. The
other terminal of load 35 is connected by line 36 to load terminal
22 of circuit breaker module 16. The ungrounded or energized
terminal of source 33 is connected by lead 37 to male stab 38 of a
panelboard (not shown), with stab 38 being removably engaged by
line terminal 21 of circuit breaker module 16.
As is well known in the art and as explained in the aforesaid U.S.
Pat. No. 3,555,359 when unequal currents flow in primary windings
28, 29 a ground fault signal is generated in secondary winding 31
of transformer 30. This signal is fed through amplifier 39 to the
control electrode of solid-state switch 41. The power circuit for
switch 41 is connected in series between one end of shunt trip coil
40 of circuit breaker module 16 and the load side of primary
winding 28. The other side of shunt trip winding 40 is connected to
the load side of primary winding 29. Amplifier 39 is energized by
power supply 42, whose input is connected to the load sides of
primary windings 28 and 29.
Crimped connector 51 (FIG. 2), at interface region 50 partially
bounded by cover 70, splices lead 45 from load terminal 22 together
with leads 55, 56 from power supply 42 and primary winding 28
respectively. Similarly, other crimped connectors 52-54 at
interface regions 50, provide the other electrical connections
between modules 16 and 17. Thus, connector 52 splices lead 46 from
coil 27 to lead 57 from primary winding 28, connector 52 splices
lead 47 from shunt trip coil 40 to lead 58 from the common terminal
of power supply 42, and connector 54 splices lead 48 from the other
terminal of shunt trip coil 40 to lead 59 from solid-state switch
41.
Housing 61 of sensor module 17 is provided with wall 62 (FIGS. 6-8)
which, in the surface thereof confronting circuit breaker module
16, is provided with parallel channels 63-66 of semi-circular
cross-section extending from barrier 67 toward the line end of
module 17. Barrier 67 is formed integrally with wall 62 and notches
in barrier 67, aligned with the respective grooves 63-66, are
provided as will hereinafter be seen to guide leads 45-48 to the
compartments on the line side of barrier 67. Parallel barriers
71-73 formed integrally with wall 62 are perpendicular to barrier
67 and extend therefrom toward the load end of module 61. Sensor
module leads 55-59 extend externally of housing 61 through the
respective apertures 95-99 in wall 62 disposed on the load side of
barrier 67.
Outboard ribs 68, 69 (FIG. 7), formed integrally with wall 62 and
extending parallel to barriers 71-73, serve to position cover 70
before securement thereof to wall 62 by one way self-tapping screws
74 received by recesses 75 in barriers 71 and 73. The interior of
modified L-shaped cover 70 is provided with parallel ribs 81-83
that cooperate with the respective barriers 71-73 to form
compartments for splicing connectors 52, 53. Compartments for
splicing connectors 51, 54 are bounded by the lip portions 84, 85
of cover 70 and the respective ribs 81, 83; splicing connectors 52,
53 are in compartments bounded by the respective pairs of cover
ribs 81, 82 and 82, 83.
As best seen in FIGS. 9 and 10, wall 86 of circuit breaker module
housing 87 is adjacent to sensor module wall 62. Wall 86 is
provided with parallel grooves 91-94 of semi-circular cross-section
extending from the load end of wall 86 partway toward the line end
thereof. Apertures 101-104 at the line ends of the respective
grooves 91-94 are provided for the passage of the respective leads
45-48 from the inside to the outside of circuit breaker module
housing 87. Grooves 91-94 confront the respective grooves 63-66 and
cooperate therewith to form channels of circular cross-sections
through which leads 45-48 extend and are guided to the load side of
barrier 67 through notches therein.
As best seen in FIGS. 3-5, the two piece housings 87, 61 for
modules 16, 17 are identical in width, with this width preferably
being one inch. Both housings 61 and 87 are provided with similar
mounting recesses 106, 107 respectively (FIG. 4) at the load ends
thereof to receive adjacent mounting hooks (not shown) spaced on
one inch centers in a common type of commerical panelboard. Leads
32, 34 for primary winding 29 extend through load end aperture 105
of sensor housing 61. The line ends of housing 61, 87 are provided
with similarly shaped slots 108, 109, respectively, which receive
adjacent male-type line stabs, such as line stabs 38 (FIG. 13) that
are disposed in a row and spaced on one inch centers in a typical
type of commercial panelboard. Line terminal 21 of circuit breaker
module 16 is aligned with slot 108 to engage the panelboard line
stab received by slots 108, and the panelboard line stab received
by slot 109 is not electrically engaged with any of the operating
elements of ground fault interrupter 15.
Thus, it is seen that the instant invention provides a novel
construction for a ground fault interrupter including a sensor
module 17 and a circuit breaker module 16, with the latter having
all of the movable mechanical elements of interrupter 15. The
making of electrical connections between modules 16 and 17 is
facilitated by providing an interface region having individual
compartments for each of the splicing elements 51-54 as well as
guide channels formed by the cooperation of grooves 63-66 with
grooves 101-104. Interrupter 15 is assembled by mechanically
securing modules 16 and 17 together, with circuit breaker module
leads 45-48 extending past the load end of module 16 and through
the notches in barrier 67. Splicing devices 51-54 are then applied
to make all electrical interconnections between modules 16 and 17.
Finally interface cover 70 is secured to sensor housing 61 to close
off interface region 50.
Although there has been described a preferred embodiment of this
novel invention, many variations and modifications will now become
apparent to those skilled in the art. Therefore, this invention is
to be limited not by the specific disclosure herein but only by the
appending claims.
* * * * *