Protective device with end-of-life indication before power denial

• US 7,843,197 B2
• Filed: 10/08/2008
• Issued: 11/30/2010
• Est. Priority Date: 06/15/2004
• Status: Expired due to Fees

• Current Assignee: Pass & Seymour Incorporated (Legrand SA)
• Original Assignee: Pass & Seymour Incorporated (Legrand SA)
• Inventors: Packard, Thomas N., Finlay, David A. Sr., Macbeth, Bruce F.
• Primary Examiner(s): NATALINI, JEFF WILLIAM
• Application Number:
  US12/247,848
• Publication Number:
  US 20090251148A1
• Time in Patent Office: 783 Days
• Field of Search: None
• US Class Current: 324/424
• CPC Class Codes: G01R 31/14 Circuits therefor , e.g. for generating test voltages, sensing circuits G01R31/1209 - G01R31/1227 take precedence; for testing switches G01R31/327
• CPC Class Codes: G01R 31/28 Testing of electronic circuits, e.g. by signal tracer EMC, EMP or similar testing of electronic circuits G01R31/002; testing for short-circuits, discontinuities, leakage or incorrect line connection G01R31/50; checking computers or computer components G06F11/00; checking static stores for correct operation G11C29/00 ; testing receivers or transmitters of transmission systems H04B17/00
• CPC Class Codes: G01R 31/2829 Testing of circuits in sensor or actuator systems testing of apparatus for measuring electric or magnetic variables G01R35/00; testing of indicating or recording apparatus G01D; in airbag systems B60R21/0173; checking gas analysers G01N33/007; monitoring or fail-safe circuits for electromagnets H01F7/1844
• CPC Class Codes: G01R 31/3277 of low voltage devices, e.g. domestic or industrial devices, such as motor protections, relays, rotation switches
• CPC Class Codes: G01R 31/52 Testing for short-circuits, leakage current or ground faults
• CPC Class Codes: G01R 35/00 Testing or calibrating of apparatus covered by the other groups of this subclass
• 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 73/045 Bridging contacts
• CPC Class Codes: H02H 3/335 the main function being self testing of the device

Abstract

The present invention is directed to an electrical wiring device that includes an automatic self-test assembly coupled to the plurality of line terminals or the plurality of load terminals, the detection circuit, the fault detection circuit and the circuit interrupter assembly. The automatic self-test assembly is configured to cause the detection circuit to generate a simulated sensor fault signal during a predetermined half-cycle of an AC line cycle in accordance with a predetermined periodic testing schedule, monitor the fault detection signal corresponding to the simulated sensor fault signal, and generate a test result signal based on monitoring the fault detection signal. The automatic self-test assembly also includes a noise immunized decision circuit configured to evaluate a plurality of test results to thereby provide a noise immunized end-of-life signal. One of the conductive paths that connects the plurality of line terminals and the plurality of load terminals being interrupted in response to the noise immunized end-of-life signal.

Claims

1. An electrical wiring device comprising:

a plurality of line terminals and a plurality of load terminals;

a sensor circuit coupled to the plurality of line terminals, the sensor circuit being configured to generate a sensor fault signal in response to at least one fault condition propagating on the plurality of line terminals and/or the plurality of load terminals;

a fault detection circuit coupled to the sensor circuit, the fault detection circuit being configured to generate a fault detection signal when the sensor fault signal exceeds a predetermined level;

a circuit interrupter assembly coupled to the fault detection circuit, the circuit interrupter assembly including a set of movable contacts configured to be driven into a tripped state in response to the fault detection signal and driven into a reset state in response to a reset actuation; and

an automatic self-test assembly coupled to the plurality of line terminals or the plurality of load terminals, the sensor circuit, the fault detection circuit and the circuit interrupter assembly, the automatic self-test assembly including,

a control circuit configured to operate in a self test mode and in a non-self test mode in accordance with a predetermined schedule, the control circuit being configured to generate a self test actuation signal during a predetermined half-cycle of selected AC line cycles while in the self test mode in accordance with the predetermined schedule,

an automated self test circuit coupled to the control circuit, the automated self test circuit being configured to generate a simulated sensor fault signal in response to the self test actuation signal, and

a monitoring circuit coupled to the fault detection circuit and the circuit interrupter assembly, the monitoring circuit being configured to monitor the response of the sensor circuit, the fault detection circuit and at least one component of the circuit interrupter assembly during the selected AC line cycles and make an end-of-life determination based on said response in accordance with predetermined noise immunized decision criteria, the monitoring circuit being further configured to generate an end-of-life detection signal based on the predetermined noise immunized decision criteria.

2. The device of claim 1, wherein the automatic self-test assembly includes at least one indicator configured to emit an indication signal in response to the end-of-life detection signal.

3. The device of claim 2, wherein the indication signal is a visual signal, an audible signal, or both.

4. The device of claim 2, wherein the at least one indicator includes at least one light emitting element.

5. The device of claim 4, wherein the at least one light emitting element is configured to emit a coded signal to indicate one of a plurality of events.

6. The device of claim 5, wherein the plurality of events includes a plurality of failure modes, the plurality of failure modes including an open solenoid, a shorted solenoid, a shorted SCR, or an open SCR.

7. The device of claim 5, wherein the plurality of events indicated includes an end-of-life state, a tripped state, or a reset state.

8. The device of claim 1, wherein the circuit interrupter assembly includes an SCR, at least one solenoid and a circuit interrupter.

9. The device of claim 8, wherein the circuit interrupter is a four-pole circuit interrupter that separates a plurality of receptacle load contacts from the plurality of line terminals and the plurality of load terminals in the tripped state.

10. The device of claim 8, wherein the at least one solenoid includes a primary solenoid and a redundant solenoid.

11. The device of claim 1, wherein the predetermined half-cycle of the AC line cycle is a predetermined half-cycle polarity of AC power.

12. The device of claim 11, wherein the predetermined half-cycle polarity of AC power is a negative polarity.

13. The device of claim 1, wherein the automatic self-test assembly includes an automated switching mechanism disposed in the automated self test circuit and configured to selectively introduce the simulated sensor fault signal on the plurality of line terminals or the plurality of load terminals.

14. The device of claim 13, wherein the automated switching mechanism includes a relay coupled to a switch disposed on a test circuit.

15. The device of claim 1, wherein the automatic self-test assembly includes a timing circuit coupled to the fault detection circuit and a test circuit coupled to the plurality of line terminals.

16. The device of claim 1, wherein the predetermined periodic testing schedule includes scheduling the simulated sensor fault signal for selected negative half-cycles of the AC cycle.

17. The device of claim 1, wherein the predetermined periodic testing schedule includes scheduling the simulated sensor fault signal every negative half-cycles of the AC cycle.

18. The device of claim 1, wherein the end-of-life signal is generated in response to a plurality of failure modes, the plurality of failure modes including an open solenoid, a shorted solenoid, a shorted SCR, or an open SCR.

19. The device of claim 1, wherein the automatic self-test assembly includes at least one indicator configured to signal an open solenoid, a shorted solenoid, a shorted SCR, or an open SCR.

20. The device of claim 1, wherein the test result signal indicates a successful test when the fault detection signal is detected, and indicates an unsuccessful test when the fault detection signal is not detected.

21. The device of claim 1, wherein the predetermined noise immunized decision criteria includes monitoring the response over a plurality of consecutive test cycles.

22. The device of claim 1, wherein the predetermined noise immunized decision criteria includes monitoring the response over a span of at least one minute.

23. The device of claim 1, further comprising a by-pass circuit configured to circumvent the control circuit and trip the circuit interrupter assembly when predetermined conditions occur.

24. The device of claim 23, wherein the predetermined conditions include a ground fault current exceeding a predetermined amplitude.

25. the device of claim 24, wherein the predetermined amplitude is greater than or equal to about 100 mA.

26. The device of claim 1, wherein the control circuit is configured to deactivate the automated self test circuit in the non-self test mode.

27. The device of claim 1, wherein the control circuit is configured to be in the non-self test mode during a predetermined non-self test mode duration in accordance with a predetermined schedule, the non-self test mode duration being selectable.

28. The device of claim 27, wherein the non-self test mode duration is within a range between one second and one month.

29. The device of claim 1, wherein at least one conductive path connecting the plurality of line terminals and the plurality of load terminals is interrupted in response to the end-of-life signal.

30. The device of claim 1, wherein the end-of-life detection signal includes an end-of-life indication signal and an end-of-life circuit interruption signal, the end-of-life indication signal being generated a predetermined time interval before the end-of-life circuit interruption signal.

31. The device of claim 30, wherein the predetermined time interval is less than or equal to about twenty-four hours.

32. The device of claim 30, wherein the predetermined time interval is less than or equal to about forty-eight hours.

33. The device of claim 1, further comprising a signal conditioning circuit disposed between the fault detection circuit, the circuit interrupting assembly and the monitoring circuit, the signal conditioning circuit being configured to provide a conditioned signal input to the monitoring circuit.

34. The device of claim 33, wherein the signal conditioning circuit includes a tank circuit.

35. The device of claim 34, wherein the tank circuit includes a trip solenoid, the trip solenoid being a portion of the circuit interrupter assembly.

36. The device of claim 33, wherein the conditioned signal input is indicative of whether the sensor circuit, the fault detection circuit, a power supply circuit, or the circuit interrupter assembly are in a failed condition.

37. The device of claim 1, further comprising an end-of-life redundancy protection circuit configured to detect and respond to an end-of-life condition in at least one component of the automatic self-test assembly.

38. The device of claim 1, wherein the automated self test circuit is configured to generate a simulated grounded neutral fault condition.

39. The device of claim 1, wherein the fault detection circuit is configured to detect a ground fault condition or an arc fault condition.

40. The device of claim 1, further comprising a wiring state detection circuit coupled between the plurality of line terminals and the plurality of load terminals, the wiring state detection circuit being configured to substantially prevent the circuit interrupter assembly from operating in the reset state if a source of AC power is improperly connected to the plurality of load terminals.

41. The device of claim 1, wherein the circuit interrupter assembly includes redundant trip solenoids.

42. The device of claim 1, further comprising a power denial mechanism coupled to the plurality of line terminals and the plurality of load terminals, the power denial mechanism being configured to open circuit at least one conductor disposed between the plurality of line terminals and the plurality of load terminals in response to the end-of-life detection signal.