Circuit interrupting device with reset lockout and reverse wiring protection and method of manufacture

• US 7,049,910 B2
• Filed: 03/20/2001
• Issued: 05/23/2006
• Est. Priority Date: 08/24/1998
• Status: Expired due to Fees

• Current Assignee: Leviton Manufacturing Company Incorporated
• Original Assignee: Leviton Manufacturing Company Incorporated
• Inventors: Ziegler, William R., Campolo, Steve, Disalvo, Nicholas L.
• Primary Examiner(s): DONOVAN, LINCOLN D
• Application Number:
  US09/812,288
• Publication Number:
  US 20020071228A1
• Time in Patent Office: 1,890 Days
• Field of Search: 335/6, 335/16, 335/18, 335165-176, 335/202, 361 42- 51
• US Class Current: 335/18
• CPC Class Codes: G01R 31/52 Testing for short-circuits, leakage current or ground faults
• CPC Class Codes: G01R 31/67 Testing the correctness of wire connections in electric apparatus or circuits
• CPC Class Codes: H01H 2083/045 Auxiliary switch opening testing circuit in synchronism with the main circuit
• CPC Class Codes: H01H 2083/201 the other abnormal electrical condition being an arc fault
• CPC Class Codes: H01H 71/524 the contact arm being pivoted on handle and mechanism spring acting between cradle and contact arm
• CPC Class Codes: H01H 71/62 with means for preventing resetting while abnormal condition persists, e.g. loose handle arrangement
• CPC Class Codes: H01H 83/04 with testing means for indicating the ability of the switch or relay to function properly
• CPC Class Codes: H02H 1/0015 Using arc detectors
• CPC Class Codes: H02H 3/335 the main function being self testing of the device
• CPC Class Codes: H02H 3/338 also responsive to wiring error, e.g. loss of neutral, break
• CPC Class Codes: H02H 5/083 responsive to the entry or leakage of a liquid into an electrical appliance moisture alarm G08B21/20

Abstract

Resettable circuit interrupting devices, such as GFCI devices, that include reverse wiring protection, and optionally an independent trip portions and/or a reset lockout portion are provided. The reverse wiring protection operates at both the line and load sides of the device so that in the event line side wiring to the device is improperly connected to the load side, fault protection for the device remains. The trip portion operates independently of a circuit interrupting portion used to break the electrical continuity in one or more conductive paths in the device. The reset lockout portion prevents the reestablishing of electrical continuity in open conductive paths if the circuit interrupting portion is non-operational, if an open neutral condition exists or if the device is reverse wired. Methods for ensuring a reset lock out state before shipment are provided.

Claims

1. A method for distributing a circuit interrupting device having a circuit interrupting portion with a circuit interrupter, and a reset portion in a housing comprising the steps of:

setting said circuit interrupting device to a tripped state, said circuit interrupting device having, within the housing, a first electrical conductor capable of being electrically connected to a source of electricity;

a second electrical conductor capable of conducting electrical current to a load when electrically connected to said first electrical conductor;

a third electrical conductor capable of being electrically connected to user accessible plugs and/or receptacles where the first, second and third electrical conductors are electrically isolated from each other;

at least one movable bridge electrically connected to the first electrical conductor, said at least one movable bridge capable of electrically connecting the first, second and third electrical conductors to each other;

said circuit interrupter portion having a circuit interrupter eleetromechanically coupled to the at least one movable bridge, which circuit interrupter when energized due to the occurrence of a predetermined condition, is capable of engaging said movable bridge causing electrical discontinuity between said first, second and third electrical conductors;

said reset portion being coupled to the circuit interrupting portion, and when said reset portion is activated, is capable of energizing the circuit interrupter which engages the at least one movable bridge causing electrical continuity between the first, second and third electrical conductors to be reestablished whereby continuity between the first, second and third electrical conductors is not reestablished when the activated reset portion is not capable of energizing the circuit interrupter; and

placing said tripped circuit interrupting device into the stream of commerce.

2. The method of claim 1 for distributing a circuit interrupting device further comprising the step of:

testing reset lockout portion before placing the circuit interrupting device into the steam of commerce.

3. The method of claim 1, wherein said reset lockout portion is adapted to be selectively electrically powered by the phase conductive path.

4. The method of claim 1, wherein said circuit interrupting device further comprises a mechanically operated mechanism for tripping said circuit interrupting device.

5. A method for distributing a circuit interrupting device having a reset lockout portion, sensing circuitry to sense the occurrence of a predetermined condition, and a circuit interrupting portion in a housing comprising the steps of:

setting said circuit interrupting device to a tripped state, said circuit interrupting device having, within the housing, a phase conductive path and a neutral conductive path between a line side and a load side;

said phase conductive path terminating at a first connection capable of being electrically connected to a source of electricity, a second connection capable of conducting electricity to at least one load and a third connection capable of conducting electricity to at least one user accessible load; and

said neutral conductive path terminating at a first connection capable of being electrically connected to a source of electricity, a second connection capable of providing a neutral connection to said at least one load and a third connection capable of providing a neutral connection to said at least one user accessible load;

said circuit interrupting portion coupled to said sensing circuitry and configured to trip the device to cause electrical discontinuity in said phase and neutral conductive paths between said line side and said load sides upon the occurrence of a predetermined condition;

said reset lockout portion being configured to reestablish electrical continuity in said phase or neutral conductive paths or both conductive paths upon being activated by electricity from said phase line side unless the circuit interrupting portion is not operating properly; and

placing said tripped circuit interrupting device into a stream of commerce.

6. A method of distributing an electrical wiring device capable of being installed in cooperation with a current carrying electrical circuit, said electrical wiring device including a reset lockout capability having a circuit interrupting portion disposed within a housing, said method comprising the steps of:

receiving said electrical wiring device in a (ripped state, said circuit interrupting portion including within the housing a phase conductive path and a neutral conductive path between a line side and a load side, said phase conductive path including a portion thereof terminating at a first electrical conducting connector which is capable of being in electrical communication with a source of electricity, a second electrical conducting connector capable of being in electrical communication with at least one load, and a third electrical conducting connector capable of being in electrical communication with at least one user accessible load, said neutral conductive path including a portion thereof terminating at a fourth electrical conducting connector capable of being in electrical communication with a source of electricity, a fifth electrical conducting connector capable of being in neutral electrical communication with said load, and a sixth electrical conducting connector capable of being in neutral electrical communication with said user accessible load,

said circuit interrupting portion being capable of causing electrical discontinuity in said phase and neutral conductive paths intermediate said line and load sides upon the occurrence of a predetermined condition,

said reset lockout capability preventing the establishment of electrical continuity in either said phase or neutral conductive paths or both conductive paths unless said reset lockout capability is operating properly, and

distributing said electrical wiring device into a steam of commerce.