Eaton Corporation

Eaton Intelligent Power Limited

Kevin Lynn Parker

Robert Tracy Elms

Theodore James Miller

Joseph C Engel

John Joseph Shea

Joseph Charles Zuercher

Xin Zhou

Jerome Kenneth Hastings

Christopher Stuart

Dale Louis Gass

David Austin Eldridge

Peter J Theisen

Birger Pahl

Engelbert Hetzmannseder

Brendan Arthur Foley

Lanson Dwight Relyea

Thomas A Domitrovich

Joseph Charles Engel

A system for diagnosing circuit protection device field issues includes a remote computer system and a diagnostic circuit protection device installed at a customer location, wherein the circuit protection device includes a processor configured to execute a number of routines, a plurality of sensors structured to sense power circuit information, a memory accessible by the processor, and a communications module coupled to the non-volatile memory. The routines are structured to input sensed power circuit information and determine trip information for one or more trip cycles and cause the stored power circuit information and trip information to be transmitted to the remote computer system by the communications module over a network for storage and subsequent access for diagnostic purposes.

Remote diagnostic system and method for circuit protection devices such as miniature circuit breakers

A direct current arc fault detector includes a first current sensor sensing an alternating current component of current flowing in a DC power circuit; a second current sensor sensing a DC component of the current; and a bandpass filter filtering the sensed AC component. A demodulating logarithmic amplifier includes an input of the filtered AC component, and an output. An integrator or minimum detector includes an input connected to the amplifier output, and an output. A processor repetitively inputs and then resets the integrator or minimum detector output, and determines an arc when, for a predetermined time: the sensed DC component being greater than a first predetermined value, and a present value of the integrator or minimum detector output being greater than or different from a previous value of such output by more than a second predetermined value, or the present value being greater than a third predetermined value.

Direct current arc fault detector and circuit interrupter, and method of detecting an arc in a direct current power circuit

A circuit interrupter for a power circuit includes separable contacts, an operating mechanism structured to open and close the separable contacts, and a trip circuit cooperating with the operating mechanism to trip open the separable contacts. The trip circuit includes a number of hardware circuits having a processor with a number of routines. The routines provide a number of protective functions structured to detect a number of faults of the power circuit, a number of repetitive test functions for the number of hardware circuits, and a supervisory function cooperating with the number of repetitive test functions. The supervisory function is structured to prevent availability of protection by the number of protective functions from falling below a predetermined threshold as a result of a plurality of intermittent error conditions of the number of hardware circuits.

Circuit interrupter including supervisory function for protective function and hardware circuit repetitive test function

A method of tripping a circuit interrupter in a back fed configuration is provided, wherein the circuit interrupter has separable contacts and an actuator, such as a solenoid, operatively coupled to the separable contacts. The method includes detecting within the circuit interrupter that a fault condition exists, and subsequent to detecting that the fault condition exists, determining whether a current is flowing within the circuit interrupter between a load side of the circuit interrupter and the separable contacts, and controlling operation of the actuator based on whether the current is flowing within the circuit interrupter.

Method of tripping a circuit interrupter in a back fed configuration

A miniature circuit breaker includes separable contacts, an operating mechanism structured to open and close the separable contacts, a trip mechanism cooperating with the operating mechanism to trip open the separable contacts, a processor having a routine, a plurality of sensors sensing power circuit information operatively associated with the separable contacts, and a non-volatile memory accessible by the processor. The routine of the processor is structured to input the sensed power circuit information, determine and store trip information for each of a plurality of trip cycles in the non-volatile memory, store the sensed power circuit information in the non-volatile memory for each of a plurality of line half-cycles, and determine and store circuit breaker information in the non-volatile memory for the operating life span of the miniature circuit breaker.

Circuit interrupter employing non-volatile memory for improved diagnostics

An arc fault circuit interrupter includes separable contacts, an operating mechanism and an arc fault detector structured to detect an arc fault condition operatively associated with the contacts. The arc fault detector includes a tuned current sensor structured to sense broadband noise of a current flowing through the contacts, a compression circuit including an input of the sensed broadband noise and an output. The compression circuit compresses the dynamic range of the sensed broadband noise. A minimum detector includes an input of the compression circuit output and an output of the minimum value of the minimum detector input. A processor includes a number of inputs and an output. One of the inputs is the output of the minimum value of the minimum detector. A trip mechanism cooperates with the output of the processor and the operating mechanism to trip open the contacts responsive to the detected arc fault condition.

Arc fault circuit interrupter and method providing improved nuisance trip rejection

A circuit breaker includes a line terminal, a load terminal, separable contacts electrically connected in series between the terminals, a neutral conductor, and an operating mechanism structured to open and close the contacts and trip open the contacts in response to a trip signal. A first sensor senses an electrical characteristic operatively associated with the contacts. A second sensor detects zero crossings, a consecutive pair of the crossings defining a corresponding half-cycle and a first frequency. A processor cooperates with the sensors and includes a routine and a timer having a second frequency. The routine determines, for each of the half-cycles and responsive to the timer, plural samples of the sensed electrical characteristic in a phase synchronized relationship to a corresponding one of the crossings, and determines whether one of the frequencies exceeds a number of corresponding predetermined values for a number of times and responsively outputs the trip signal.

Circuit interrupter and method of processor phase synchronization

An arc fault circuit interrupter includes line and load terminals, separable contacts in series between the terminals, a neutral conductor, and an operating mechanism opening and closing the contacts and tripping open the contacts in response to a trip signal. A current transformer senses current flowing through the contacts. A voltage sensor detects voltage zero crossings between the load terminal and the neutral conductor. A processor detects a resistive series arc in series with the contacts. A processor routine determines, for each half cycle, samples of the sensed current, an offset value from an average of sensed current samples proximate the voltage zero crossings for the corresponding half cycle, adjusted sensed current samples as adjusted by the offset value, a profile corresponding to a resistive series arc as a function of the sensed current samples and the adjusted samples, and the trip signal in response to occurrences of the profile.

Arc fault circuit interrupter and method of detecting and interrupting a resistive series arc of a power circuit

A circuit breaker includes separable contacts, an operating mechanism structured to open and close the separable contacts, a current sensor structured to sense current flowing through the separable contacts, a microprocessor cooperating with the sensor and the operating mechanism to trip open the separable contacts, and a power supply structured to at least power the microprocessor. The microprocessor includes a configurable clock and a routine structured to reduce current consumption from the power supply through modulation of the configurable clock.

Circuit interrupter and method modulating configurable processor clock to provide reduced current consumption

An arc fault circuit interrupter includes separable contacts, an operating mechanism, a current sensor sensing current flowing through the contacts and outputting a sensed current, and a processor determining and storing peak values of the sensed current for plural half-cycles. The processor provides arc fault detection, determines whether a first predetermined plurality of half-cycles occur in succession and correspond to non-unity power factor, and responsively inhibits the detection for a first predetermined time, and whether a second predetermined plurality of half-cycles occur in succession, each with smaller peak amplitude than that of an immediately preceding half-cycle of like or differing polarity, and responsively inhibits the detection for a second predetermined time. The processor determines that the detection is not inhibited for the first and second predetermined times, and responsively indicates that any of the half-cycles having a peak amplitude greater than a predetermined amount is a parallel arc.

Arc fault circuit interrupter and method of parallel arc fault detection

A circuit interrupter includes band pass filters cooperating with a current sensor to output bands having different, non-overlapping ranges of frequencies, peak detectors cooperating with the filters to detect corresponding peak current values, envelope detectors cooperating with the filters to detect corresponding occurrences from the bands being within corresponding predetermined magnitude ranges, a counter counting the occurrences, and a processor providing and disabling series arc detection when sensed current is greater than a first predetermined value. The processor determines tallies responsive to peak current values exceeding corresponding thresholds, determines series arcing from sensed current being less than the first predetermined value for a predetermined time, the tally for a current half-cycle being nonzero, and a count for the current half-cycle being different than the count for an immediately previous half-cycle of like polarity by at least a second predetermined value. A series chaos accumulator is increased responsive to series arcing.

Arc fault circuit interrupter and series arc fault detection method using plural high frequency bands

A circuit breaker includes separable contacts, an operating mechanism structured to open and close the separable contacts, and a trip mechanism. The trip mechanism includes a sensor structured to sense current flowing through the separable contacts, a processor cooperating with the sensor to determine a plurality of different trip conditions responsive to the sensed current, a nonvolatile memory operatively associated with the processor, and a trip actuator cooperating with the processor and the operating mechanism to trip open the separable contacts responsive to one of the different trip conditions from the processor. The processor is structured to save in and retrieve from the nonvolatile memory cause-of-trip information for the different trip conditions including the one of the different trip conditions.

Circuit interrupter including nonvolatile memory storing cause-of-trip information

An arc fault and/or ground fault circuit interrupter includes an operating mechanism structured to open and close separable contacts, a trip mechanism cooperating with the operating mechanism to trip open the separable contacts, a test button structured to test the operating mechanism, an indicator, and a controller structured to configure a setting of the circuit interrupter and operate the indicator to indicate the setting in response to an actuation of the test button.

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Pittsburgh, PA, United States of America

Kevin Lynn Parker