GFCI with miswire lockout

• US 7,212,386 B1
• Filed: 04/12/2005
• Issued: 05/01/2007
• Est. Priority Date: 11/21/2000
• Status: Expired due to Term

• Current Assignee: Pass And Seymour Incorporated (Legrand SA)
• Original Assignee: Pass And Seymour Incorporated (Legrand SA)
• Inventors: Weeks, Richard, Packard, Thomas N., Finlay, David A. Sr.
• Primary Examiner(s): Jackson; Stephen W.
• Assistant Examiner(s): Benenson; Boris
• Application Number:
  US11/103,722
• Time in Patent Office: 749 Days
• Field of Search: 361/42, 361/45, 361/46
• US Class Current: 361/42
• CPC Class Codes: H01H 2071/044 Monitoring, detection or measuring systems to establish the end of life of the switching device, can also contain other on-line monitoring systems, e.g. for detecting mechanical failures
• 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 3/338 also responsive to wiring error, e.g. loss of neutral, break

Abstract

The present invention is directed to an electrical wiring protection device that includes a housing assembly having at least one line terminal and at least one load terminal partially disposed therein. A first conductive path is electrically coupled to the at least one line terminal. A second conductive path is electrically coupled to the at least one load terminal, the second conductive path being connected to the first conductive path in a reset state. A fault detection circuit is coupled to the first conductive path. The fault detection circuit is configured to generate a fault detection signal in response to detecting at least one fault condition. A wiring state detection circuit is coupled to the first conductive path. The wiring state detection circuit selectively provides a wiring state detection signal when the at least one line terminal is coupled to a source of AC power, and not providing the wiring state detection signal otherwise. An actuator assembly is configured to provide an actuation stimulus in response to the fault detection signal or the wiring state detection signal. A circuit interrupter is coupled to the actuator assembly. The circuit interrupter is configured to disconnect the first conductive path and the second conductive path in response to the actuation stimulus.

Claims

1. An electrical wiring protection device comprising:

a housing assembly including at least one line terminal and at least one load terminal partially disposed therein;

a first conductive path electrically coupled to the at least one line terminal;

a second conductive path electrically coupled to the at least one load terminal, the second conductive path being connected to the first conductive path in a reset state;

a fault detection circuit coupled to the first conductive path, the fault detection circuit being configured to generate a fault detection signal in response to detecting at least one fault condition;

a wiring state detection circuit coupled to the first conductive path, the wiring state detection circuit selectively providing a wiring state detection signal when the at least one line terminal is coupled to a source of AC power;

an actuator assembly configured to provide an actuator signal in response to the fault detection signal or the wiring state detection signal; and

a circuit interrupter coupled to the actuator assembly, the circuit interrupter being configured to disconnect the first conductive path from the second conductive path in response to the actuator signal in the reset state.

2. The device of claim 1, further comprising:

a reset button; and

a switch coupled between the reset button and the wiring state detection circuit, the reset button being configured to close the switch to thereby generate the wiring state detection signal.

3. The device of claim 2, wherein the actuator assembly further comprises:

an electronic switch including a control input coupled to the switch; and

a solenoid coupled between the control input and the circuit interrupter.

4. The device of claim 3, wherein the coil includes an armature configured to open circuit the phase conductive path, the neutral conductive path, or both, when the solenoid is energized.

5. The device of claim 4, further comprising a lock-out mechanism coupled to the armature and the circuit interrupter, the lock-out mechanism preventing the reset button from effecting reset in the absence of the wiring state detection signal.

6. The device of claim 2, wherein the actuator assembly further comprises a solenoid coupled to the circuit interrupter, the wiring state detection circuit including the switch being disposed in series with the coil.

7. The device of claim 2, wherein the wiring state detection circuit includes a resistor disposed in series with the switch.

8. The device of claim 1, further comprising at least one user load terminal coupled to the first conductive path by way of a third conductive path, the third conductive path being connected to the first conductive path in a reset state, and the circuit interrupter being configured to disconnect the first conductive path and the third conductive path in response to the actuation stimulus.

9. An electrical wiring protection device comprising:

a housing assembly including at least one line terminal and at least one load terminal partially disposed therein;

a first conductive path electrically coupled to the at least one line terminal;

a second conductive path electrically coupled to the at least one load terminal, the second conductive path being connected to the first conductive path in a reset state;

a fault detection circuit coupled to the first conductive path, the fault detection circuit being configured to generate a fault detection signal in response to detecting at least one fault condition;

a reset button coupled to the at least one line terminal;

a wiring state detection circuit coupled to the reset button, the wiring state detection circuit selectively providing a wiring state detection signal when the reset button is actuated and the at least one line terminal is coupled to a source of AC power;

an actuator assembly configured to provide an actuation stimulus in response to the fault detection signal or the wiring state detection signal; and

a circuit interrupter coupled to the actuator assembly, the circuit interrupter being configured to disconnect the first conductive path and the second conductive path in response to the actuation stimulus in the reset state.

10. The device of claim 9, wherein the reset button includes switch contacts coupled to the wiring state detection circuit.

11. The device of claim 10, wherein the actuator assembly further comprises:

an electronic switch; and

a solenoid coupled to the circuit interrupter.

12. The device of claim 11, wherein the coil includes an armature configured to disconnect the first conductive path and the second conductive path when the solenoid is energized.

13. The device of claim 12, further comprising a lock-out mechanism coupled to the armature and the circuit interrupter, the lock-out mechanism preventing the reset button from effecting reset in the absence of the wiring state detection signal.

14. The device of claim 10, wherein the actuator assembly further comprises a coil coupled to the circuit interrupter, the wiring state detection circuit including the switch contacts being disposed in series with the coil.

15. The device of claim 9, further comprising at least one user load terminal coupled to the first conductive path by way of a third conductive path, the third conductive path being connected to the first conductive path in a reset state, and the circuit interrupter being configured to disconnect the first conductive path and the third conductive path in response to the actuation stimulus.

16. An electrical wiring protection device comprising:

a housing assembly including at least one line terminal and at least one load terminal partially disposed therein;

a first conductive path electrically coupled to the at least one line terminal;

a second conductive path electrically coupled to the at least one load terminal, the second conductive path being connected to the first conductive path in a reset state;

a fault detection circuit coupled to the first conductive path, the fault detection circuit being configured to generate a fault detection signal in response to detecting at least one fault condition;

a reset mechanism coupled to the at least one line terminal;

a wiring state detection circuit coupled to the reset mechanism, the wiring state detection circuit selectively providing a wiring state detection signal when the reset mechanism is actuated and the at least one line terminal is coupled to a source of AC power;

an actuator assembly configured to provide an actuation stimulus in response to the fault detection signal or the wiring state detection signal;

a circuit interrupter coupled to the actuator assembly, the circuit interrupter being configured to disconnect the first conductive path and the second conductive path in response to the actuation stimulus in the reset state; and

a reset lockout coupled to the circuit interrupter, the reset lockout preventing the circuit interrupter from reconnecting the first conductive path and the second conductive path in response to an actuation of the reset mechanism in the absence of the wiring state detection signal.

17. The device of claim 16, further comprising at least one user load terminal coupled to the first conductive path by way of a third conductive path, the third conductive path being connected to the first conductive path in a reset state, and the circuit interrupter being configured to disconnect the first conductive path and the third conductive path in response to the actuation stimulus.

18. The device of claim 17, wherein the reset mechanism includes a reset button coupled to a switch, an actuation of the reset button causing the switch to close.

19. The device of claim 18, wherein the wiring state detection circuit includes a resistor connected in series with the switch.

20. The device of claim 19, wherein the actuator assembly includes an electronic switch disposed in series with a solenoid.

21. The device of claim 18, wherein the wiring state detection circuit includes the switch, the switch being coupled to a control input of the actuator assembly.

22. The device of claim 21, wherein the actuator assembly includes an electronic switch disposed in series with a solenoid, the electronic switch including the control input.

23. A circuit interrupting device comprising:

a housing;

a phase conductive path and a neutral conductive path each disposed at least partially within said housing 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;

a circuit interrupting portion disposed within said housing and configured to cause electrical discontinuity in said phase and neutral conductive paths between said line side and said load side upon the occurrence of a predetermined condition; and

a reset portion disposed at least partially within said housing and configured to reestablish electrical continuity in said phase and neutral conductive paths;

said circuit interrupting device further comprising a reset lockout portion that prevents reestablishing electrical continuity in said phase and neutral conductive paths if a reverse wiring condition exists, wherein said reset portion comprises;

a reset button; and

at least one reset contact which when depressed is capable of contacting at least a portion of said phase conductive path to cause said circuit interrupting portion to operate if said device is properly wired, wherein if said circuit interrupting portion is operational, the circuit interrupting portion is activated to disable said reset lockout portion and facilitate reestablishing electrical continuity in said phase and neutral conductive paths, and wherein if said reverse wiring condition exists said circuit interrupting portion is non-operational, said reset lockout portion remains enabled so that reestablishing electrical continuity in said phase and neutral conductive paths is prevented.

24. A circuit interrupting device comprising:

a housing;

a first electrical conductive path disposed at least partially within said housing and terminating at a first connection, said first connection being capable of electrically connecting to a source of electricity;

a second electrical conductive path disposed at least partially within said housing and terminating at a second connection, said second connection being capable of electrically connecting to at least one load when electrical continuity between said first and second electrical conductive paths is made;

a third electrical conductive path disposed at least partially within said housing and terminating at a third connection, said third connection being capable of electrically connecting to at least one user accessible load when electrical continuity between said first and third electrical conductive paths is made;

a circuit interrupting portion disposed within said housing and configured to break electrical continuity between said first and second conductive paths and between said first and third conductive paths upon the occurrence of a predetermined condition; and

a reset portion disposed at least partially within said housing and configured to make electrical continuity between said first and second conductive paths and between said first and third conductive paths;

said circuit interrupting device further comprising a reset lockout portion that prevents the making of electrical continuity between said first and second conductive paths and between said first and third conductive paths, if said circuit interrupting portion is non-operational;

and wherein said reset portion comprises,

a reset button; and

at least one reset contact which when depressed is capable of contacting at least a portion of one of said first or second conductive paths to cause said circuit interrupting portion to operate if said device is properly wired, wherein if said circuit interrupting portion is operational, said circuit interrupting portion is activated to disable said reset lockout portion and facilitate making of electrical continuity between said first and second conductive paths and between said first and third conductive paths, and wherein if said device is reverse wired said circuit interrupting portion is non-operational, said reset lockout portion remains enabled so that making of electrical continuity between said first and second conductive paths and between said first and third conductive paths is prevented.

25. A circuit interrupting device comprising:

a housing;

at least one input conductor disposed at least partially within said housing and capable of being electrically connected to a source of electricity;

at least one output conductor disposed within said housing and capable of conducting electrical current to a load when electrically connected to said at least one input conductor;

a circuit interrupter disposed within said housing and configured to break said electrical connection between said input and output conductors in response to the occurrence of a predetermined condition;

a reset lock-out operable between a lock-out position wherein said reset lock-out inhibits resetting of said electrical connection between said input and output conductors, and a reset position wherein said reset lock-out does not inhibit resetting of said electrical connection between said input and output conductors; and

a reset mechanism operatively associated with said reset lock-out and said circuit interrupter such that activation of said reset mechanism activates said circuit interrupter if said device is properly wired to facilitate movement of said reset lock-out from said lock-out position to said reset position by said reset mechanism, said reset mechanism does not activate said circuit interrupter if said device is reverse wired such that said reset lock-out remains in said lock-out position.

26. A ground fault circuit interrupting device comprising:

a housing;

at least one input conductor disposed at least partially within said housing and capable of being electrically connected to a source of electricity;

at least one output conductor disposed within said housing an capable of conducting electrical current to a load when electrically connected to said at least one input conductor;

a circuit interrupter disposed within said housing and configured to break said electrical connection between said input and output conductors in response to the occurrence of a ground fault or test cycle; and

a reset mechanism having a reset lock-out responsive to activation of said circuit interrupter so as to be movable between a lock-out position wherein said reset lock-out inhibits resetting of said electrical connection between said input and output conductors and a reset position wherein said reset lock-out does not inhibit resetting of said electrical connection between said input and output conductors, wherein when actuation of said reset mechanism in a proper wiring condition activates said circuit interrupter to facilitate movement of said reset lock-out from said lock-out position to said reset position by said reset mechanism and resets said electrical connection between said input and output conductors, and wherein actuation of said reset mechanism in a reverse wiring condition does not activate said circuit interrupter to facilitate movement of said reset lock-out from said lock-out position to said reset position.

27. A method for interrupting and resetting electrical connections in fault interrupting devices having a housing, an input conductor disposed at least partially within the housing and electrically connected to a source of electricity, and an output conductor disposed at least partially within the housing and capable of conducting electrical current to a load when electrical continuity between the input and output conductors is made, said method comprising:

sensing the occurrence of a predefined condition;

breaking electrical continuity between the input and output conductors when said predefined condition is sensed using a circuit interrupting mechanism;

enabling a lock-out mechanism to inhibit the making of electrical continuity between the input and output conductors after breaking electrical continuity between said conductors; and

activating a reset mechanism to activate said circuit interrupting mechanism to disable said lock-out mechanism and make electrical continuity between said input and output conductors if said input connector is coupled to AC power, and wherein said circuit interrupting mechanism is not activated if said input connector is not coupled to AC power.

28. The method of claim 27, wherein said circuit interrupting mechanism is not activated if said output connector is coupled to AC power.

29. A circuit interrupting device, comprising:

a line side connection capable of being electrically connected to a source of electricity;

a load side connection capable of being electrically connected to a load side conductor for providing electricity to a load side;

a user load connection capable of conducting electricity to at least one load for providing an electrical connection to the source of electricity;

a first conductive path providing an electrical connection between the line side connection and the user load connection;

a second conductive path providing an electrical connection between the line side connection and the load side connection;

a reset mechanism;

a fault detection circuit configured to detect a fault condition;

a wiring state detector separate from the fault detection circuit, the wiring state detector being configured to test for a proper wiring condition when the reset mechanism is actuated; and

a circuit interrupter configured to interrupt the at least one of the first conductive path or the second conductive path when a proper wiring condition or a fault condition is detected.

30. The device of claim 29, wherein the wiring state detector generates a proper wiring condition signal if the line side connection is electrically connected to a source of electricity and does not generate a proper wiring condition signal otherwise.

31. An electrical wiring protection device comprising:

at least one line conductor;

at least one load conductor connected to the at least one line conductor in a reset state and disconnected from the at least one line conductor in a tripped state;

a first detection circuit coupled to the at least one line conductor, the first detection circuit being configured to propagate a first detection signal in response to a predetermined signal propagating on the at least one line conductor;

a second detection circuit coupled to the at least one line conductor, the second detection circuit configured to determine whether a source of AC power is coupled to the at least one line conductor or the at least one load conductor;

an actuator assembly coupled to the first detection circuit and the second detection circuit; and

a circuit interrupter coupled to the actuator assembly, the circuit interrupter being configured to trip in response to an actuator assembly input, the second detection circuit preventing the circuit interrupter from operating in the reset state when the source of AC power is coupled to the at least one load conductor.

32. The device of claim 31, wherein the actuator assembly includes at least one switching element.

33. The device of claim 31, wherein the actuator assembly includes a reset mechanism.

34. An electrical wiring protection device comprising:

at least one line conductor;

at least one load conductor connected to the at least one line conductor in a reset state and disconnected from the at least one line conductor in a tripped state;

a fault detection circuit coupled to the at least one line conductor, the fault detection circuit being configured to generate a fault detection signal in response to a predetermined signal propagating on the at least one line conductor;

an actuator coupled to the fault detection circuit and configured to generate a stimulus in response to the fault detection signal;

a circuit interrupter configured to be driven into the tripped state in response to the stimulus;

a reset mechanism configured to drive the circuit interrupter from the tripped state into the reset state; and

a miswire detection circuit coupled to the at least one line conductor, the miswire detection circuit being configured to prevent device operation in the reset state when the at least one load conductor is coupled to AC power.

35. An electrical wiring protection device comprising:

at least one line conductor;

at least one load conductor connected to the at least one line conductor in a reset state and disconnected from the at least one line conductor in a tripped state;

a fault detection circuit coupled to the at least one line conductor, the fault detection circuit being configured to propagate a fault detection signal in response to a predetermined signal propagating on the at least one line conductor;

a circuit interrupter assembly coupled to the fault detection circuit and configured to trip in response to the fault detection signal; and

a second circuit coupled between the at least one line conductor and the circuit interrupter assembly, the second circuit precluding device reset when the at least one load conductor is coupled to AC power.

36. The device of claim 35, wherein the circuit interrupter assembly further comprises:

at least one switching element;

at least one solenoid element coupled to the at least one switching element; and

a circuit interrupter coupled to the at least one solenoid element.

37. The device of claim 36, further comprising a reset mechanism coupled to the circuit interrupter, the reset mechanism being configured to drive the circuit interrupter from the tripped state to the reset state.

38. The device of claim 36, wherein the second circuit is configured to provide the circuit interrupter assembly with a trip signal when the at least one load conductor is coupled to AC power.

39. The device of claim 38, wherein the trip signal is immediately provided to the circuit interrupter assembly when the reset mechanism is actuated.