Protective device for an electrical supply facility

• US 8,405,939 B2
• Filed: 03/08/2010
• Issued: 03/26/2013
• Est. Priority Date: 03/08/2010
• Status: Active Grant

• Current Assignee: Pass & Seymour Incorporated (Legrand SA)
• Original Assignee: Pass & Seymour Incorporated (Legrand SA)
• Inventors: Haines, Joshua P., Morgan, Kent R., Mueller, Brian
• Primary Examiner(s): Fureman, Jared
• Assistant Examiner(s): BAUER, SCOTT ALLEN
• Application Number:
  US12/719,416
• Publication Number:
  US 20110216453A1
• Time in Patent Office: 1,114 Days
• Field of Search: 361/42, 361/49, 361/50
• US Class Current: 361/42
• CPC Class Codes: B60L 2240/545 Temperature
• CPC Class Codes: B60L 2240/547 Voltage
• CPC Class Codes: B60L 2240/549 Current
• CPC Class Codes: G01R 31/52 Testing for short-circuits, leakage current or ground faults
• CPC Class Codes: H02H 3/16 responsive to fault current to earth, frame or mass with balanced or differential arrangement H02H3/26 ; monitoring earth connection H02H5/105
• CPC Class Codes: H02H 5/105 responsive to deterioration or interruption of earth connection for preventing switching-on H02H11/001
• CPC Class Codes: H02H 9/00 Emergency protective circuit arrangements for limiting excess current or voltage without disconnection

Abstract

The present invention is directed to an electrical device configured to be disposed in an electrical distribution system between a source of electrical power and an electrical load. The electrical distribution system includes at least one line hot conductor, a line neutral conductor, and a line ground conductor. The line neutral conductor is connected to the line ground conductor at a termination point in the electrical distribution system. The electrical load includes at least one load hot conductor, a load neutral conductor, and a load ground conductor. The device includes a grounding confirmation circuit that includes at least one signal generator that directs at least one test signal into a current path that includes at least the line ground conductor. The grounding confirmation circuit is configured to determine a ground continuity status of the current path based on at least one ground continuity measurement. The circuit interrupter is prevented from entering the reset state if the at least one ground continuity measurement does not meet a predefined quality threshold. The at least one ground continuity measurement being a function of the at least one electrical load parameter after the circuit interrupter is in the reset state.

Claims

1. An electrical device configured to be disposed in an electrical distribution system between a source of electrical power and an electrical load, the electrical distribution system including at least one line hot conductor, a line neutral conductor, and a line ground conductor, the line neutral conductor being connected to the line ground conductor at a termination point in the electrical distribution system, the electrical load including at least one load hot conductor, a load neutral conductor, and a load ground conductor, the device comprising:

a power input mechanism including a plurality of line termination elements and a line ground termination element, the plurality of line termination elements being configured to terminate the at least one line hot conductor and the line neutral conductor, the line ground termination element being configured to terminate the line ground conductor, the power input mechanism being configured to direct electric power provided by the source of electrical power into the device;

a power output mechanism including a plurality of load termination elements and a load ground termination element, the plurality of load termination elements being configured to terminate the at least one load hot conductor and the load neutral conductor, the load ground termination element being configured to terminate the load ground conductor, the power output mechanism being configured to direct electric power provided by the source of electrical power via the power input mechanism to the electrical load;

a circuit interrupter mechanism coupled to the fault detection circuit, the circuit interrupter mechanism being configured to interrupt electrical continuity between the plurality of line termination elements and the plurality of load termination elements in a tripped state and establish electrical continuity between the plurality of line termination elements and the plurality of load termination elements in a reset state;

a ground relay configured to couple the line ground conductor and the load ground conductor in a closed state and decouple the line ground conductor from the load ground conductor in an open state;

a grounding confirmation circuit coupled to the ground relay and the circuit interrupter mechanism, the grounding confirmation circuit being configured to prevent the ground relay from closing if ground continuity in the line ground conductor is not detected, the grounding confirmation circuit also being configured to subsequently prevent the circuit interrupter from being reset if ground continuity in the load ground conductor is not detected; and

a power supply coupled to the at least one line hot conductor and the line neutral conductor, the power supply being configured to provide DC power to the grounding confirmation circuit and electrically isolate the grounding confirmation circuit from the at least one line hot conductor.

2. The device of claim 1, wherein the grounding confirmation circuit further comprises:

a first grounding test circuit configured to determine a line ground continuity status of the line ground conductor based on at least one line electrical parameter detected by the first grounding test circuit;

a second grounding test circuit configured to determine a load ground continuity status of the load ground conductor based on at least one load electrical parameter detected by the second grounding test circuit; and

a grounding evaluation circuit configured to establish an open/closed state of the ground relay in accordance with the line ground continuity status, the grounding evaluation circuit also being configured to establish a state of the circuit interrupter in accordance with the load ground continuity status.

3. The device of claim 2, wherein the power supply is configured to provide power to the first grounding test circuit and the second grounding test circuit, the first grounding test circuit and the second grounding test circuit being electrically isolated from the at least one line hot conductor.

4. The device of claim 2, wherein the at least one line electrical parameter detected by the first grounding test circuit indicates if an impedance of the line ground conductor is greater than a first predetermined threshold, and wherein the at least one load electrical parameter detected by the second grounding test circuit indicates if an impedance of the load ground conductor is greater than a second predetermined threshold.

5. The device of claim 2, wherein the grounding confirmation circuit is configured to trip the circuit interrupter when the load ground continuity status of the load ground conductor indicates that a ground discontinuity is present.

6. The device of claim 2, wherein the grounding confirmation circuit is configured to trip the circuit interrupter when the line ground continuity status of the line ground conductor indicates that a ground discontinuity is present.

7. The device of claim 1, wherein the first grounding test circuit determines a line ground continuity status via a first test signal that does not propagate through the at least one line hot conductor, and wherein the second grounding test circuit determines a load ground continuity status via a second test signal that does not propagate through the at least one load hot conductor.

8. The device of claim 7, wherein the first test signal is derived from a DC current source.

9. The device of claim 7, wherein the first test signal or the second test signal is initiated by a processor.

10. The device of claim 9, wherein the processor prohibits the first test signal or the second test signal from occurring while a self-test is taking place.

11. The device of claim 7, wherein the first test signal includes a pulse signal of predetermined duration.

12. The device of claim 1, further comprising a processor coupled to the grounding confirmation circuit, the processor being configured to direct the grounding confirmation circuit to determine whether ground continuity in the line ground conductor or ground continuity in the load ground conductor are established.

13. The device of claim 1, wherein the grounding confirmation circuit includes a first grounding test circuit configured to determine a line ground continuity status of the line ground conductor, the first grounding test circuit further comprising:

a first signal generation circuit configured to direct a ground continuity monitoring current into the line ground conductor; and

a first comparator circuit coupled to the first signal generation circuit via the line ground conductor, the first comparator circuit being configured to compare at least one electrical parameter with at least one predetermined reference parameter to thereby determine a line ground continuity status of the line ground conductor.

14. The device of claim 13, wherein the ground continuity monitoring current is a DC current.

15. The device of claim 13, wherein the ground continuity monitoring current is an AC current.

16. The device of claim 15, wherein the AC current and the source of electrical power are characterized by a substantially identical frequency.

17. The device of claim 13, wherein the first signal generation circuit includes a DC signal source.

18. The device of claim 17, wherein the first signal generation circuit includes an AC signal source.

19. The device of claim 1, further comprising a conditioning circuit coupled to the power input mechanism and configured to direct a circulating current onto the line neutral conductor, the line neutral conductor and the ground line conductor comprising a negative feedback loop, the circulating current substantially conforming to a waveshape of a ground fault current propagating in the electric load, the waveshape of the ground fault current not being predetermined.

20. The device of claim 19, wherein the grounding confirmation circuit includes a first grounding test circuit configured to derive a line ground continuity signal from the conditioning signal and compare at least one electrical parameter of the line ground continuity signal to at least one predetermined electrical parameter to determine a line ground continuity status of the line ground conductor.

21. The device of claim 20, wherein the line ground continuity signal includes an AC signal.

22. The device of claim 21, wherein the AC current and the source of electrical power are characterized by a substantially identical frequency.

23. The device of claim 20, wherein the at least one predetermined electrical parameter is a signal magnitude.

24. The device of claim 20, wherein the first grounding test circuit includes a first comparator and a second comparator coupled to inputs of a digital logic gate, the first comparator being configured to compare a signal minima parameter to a predetermined signal minima parameter, the second comparator being configured to compare a signal maxima to a predetermined signal maxima parameter.

25. The device of claim 24, wherein the digital logic gate is selected from a group of digital logic gates that includes an OR gate and a NOR gate.

26. The device of claim 20, wherein the line ground continuity signal is derived from a composite signal comprising the conditioning signal less a signal component corresponding to an electrical load current.

27. The device of claim 20, wherein the line ground continuity signal is derived from a composite signal comprising the conditioning signal less a signal component corresponding to a background initialization current.

28. The device of claim 1, further comprising a conditioning circuit coupled to the power input mechanism, the grounding confirmation circuit deriving an input signal from the conditioning circuit, the input signal serving to desensitize the grounding confirmation circuit to the presence of the ground fault current.

29. The device of claim 28, wherein the conditioning circuit generates an output signal in response to both a ground fault current and a ground discontinuity condition, the grounding confirmation circuit being configured to detect the ground discontinuity condition based on the magnitude of the output signal.

30. The device of claim 28, wherein the conditioning circuit includes a voltage source configured to provide an output voltage, the output voltage being a function of a ground fault current and a line ground test current.

31. The device of claim 30, wherein the voltage source is coupled to the line neutral termination element by way of a resistance element.

32. The device of claim 30, wherein the voltage source is coupled to the line neutral termination element by way of a tri-state gating element configured to decouple the voltage source from voltage impulses occurring on the neutral conductor.

33. The device of claim 30, further including a ground fault detector, the ground fault current being directed to the ground fault detector via the conditioning circuit.

34. The device of claim 33, wherein the ground fault detector is coupled to a circuit interrupter, the ground fault detector being configured to drive the circuit interrupter into the tripped state in response to detecting a ground fault condition based on the ground fault current.

35. The device of claim 28, wherein the conditioning circuit includes a differential transformer configured to sense a differential current propagating in the neutral conductor and the at least one hot conductor, the differential current being generated due to a simulated ground fault current and/or a ground fault current.

36. The device of claim 35, further comprising an impedance circuit coupled to the at least one line hot conductor and the line neutral conductor, the impedance circuit being configured to generate the simulated ground fault current.

37. The device of claim 36, wherein the impedance circuit is permanently coupled to the at least one line hot conductor and the line neutral conductor.

38. The device of claim 35, further comprising an impedance circuit coupled to the at least one line hot conductor and the line neutral conductor, the impedance circuit being configured to generate a background fault current, the background fault current being a component part of the ground fault current, the background fault current being extant when the circuit interrupter is tripped and the ground relay is open such that the circulating current propagates in the negative feedback loop when the circuit interrupter is tripped and the ground relay is open.

39. The device of claim 1, wherein the power input mechanism is configured as a set of electrical wires being terminated by a connector.

40. The device of claim 1, wherein the grounding confirmation circuit detects ground continuity in the line ground conductor whether the power input mechanism manifests a proper wiring condition or a reverse polarity wiring condition.

41. The device of claim 40, wherein the grounding confirmation circuit prevents the ground relay from entering the closed state if the at least one line hot conductor is coupled to the line ground termination mechanism.

42. The device of claim 1, wherein the grounding confirmation circuit prevents the ground relay from entering the closed state if it detects a ground discontinuity in the line ground conductor.

43. The device of claim 1, wherein the grounding confirmation circuit prevents the circuit interrupter from being reset if it detects a ground discontinuity in the load ground conductor.

44. The device of claim 1, wherein the grounding confirmation circuit is coupled between a line neutral termination element of the plurality of line termination elements and a line ground termination element of the plurality of line termination elements, a ground test signal being circulated around an electrical loop comprising the line neutral conductor and the line ground conductor.

45. The device of claim 44, further including a polarity reversal circuit configured to detect a reverse wired condition in which the at least one line hot conductor and the line neutral conductor have been reverse wired to the plurality of line termination elements.

46. The device of claim 45, wherein the grounding confirmation circuit and the polarity reversal circuit are configured such that the ground test signal is circulated around an electrical loop comprising the line neutral conductor and the line ground conductor even when there is a reverse wired condition.

47. The device of claim 1, wherein the grounding confirmation circuit further comprises:

a load grounding test circuit including a test wire coupled to a test terminal disposed in the power output mechanism, the load grounding test circuit generating a load ground test signal propagating in a circuit formed by the test wire and the load ground conductor;

a load grounding comparator circuit coupled to the load grounding test circuit, the load grounding comparator circuit being configured to compare at least one electrical parameter derived from the load ground test signal with at least one predetermined reference parameter to thereby determine a load ground continuity status of the load ground conductor;

a grounding evaluation circuit configured to establish a state of the circuit interrupter in accordance with the load ground continuity status.

48. The device of claim 47, wherein the load ground test signal includes a square wave having a predetermined amplitude.

49. The device of claim 1, wherein the grounding confirmation circuit includes a first grounding test circuit configured to determine a line ground continuity status of the line ground conductor, the first grounding test circuit further comprising:

a first circuit configured to convert a pulse width modulated signal into a DC signal, the DC signal having an instantaneous magnitude that is proportional to a pulse width of the pulse width modulated signal;

a current path including the line ground conductor, the current path being configured to propagate the DC signal;

a decision circuit coupled to a return portion of the current path, the decision circuit being configured to compare at least one electrical parameter with a predetermined threshold value to determine whether the ground continuity in the line ground conductor is established.

50. The device of claim 49, wherein the predetermined threshold value corresponds to an impedance value that is greater than or equal to approximately 20 Ohms.

51. An electrical device configured to be disposed in an electrical distribution system between a source of electrical power and an electrical load, the electrical distribution system including at least one line hot conductor, a line neutral conductor, and a line ground conductor, the line neutral conductor being connected to the line ground conductor at a termination point in the electrical distribution system, the electrical load including at least one load hot conductor, a load neutral conductor, and a load ground conductor, the device comprising:

a power input mechanism including a plurality of line termination elements and a line ground termination element, the plurality of line termination elements being configured to terminate the at least one line hot conductor and the line neutral conductor, the line ground termination element being configured to terminate the line ground conductor, the power input mechanism being configured to direct electric power provided by the source of electrical power to the protective device;

a power output mechanism including a plurality of load termination elements and a load ground termination element, the plurality of load termination elements being configured to terminate the at least one load hot conductor and the load neutral conductor, the load ground termination element being configured to terminate the load ground conductor, the power output mechanism being configured to direct electric power provided by the source of electrical power via the power input mechanism to the electrical load;

a circuit interrupter mechanism coupled to the fault detection circuit, the circuit interrupter mechanism being configured to interrupt electrical continuity between the plurality of line termination elements and the plurality of load termination elements in a tripped state and establish electrical continuity between the plurality of line termination elements and the plurality of load termination elements in a reset state;

a load sensing element configured to sense at least one electrical load parameter associated with the electric load; and

a grounding confirmation circuit including at least one signal generator that directs at least one test signal into a current path that includes at least the line ground conductor, the grounding confirmation circuit being configured to determine a ground continuity status of the current path based on at least one ground continuity measurement, the circuit interrupter being prevented from entering the reset state if the at least one ground continuity measurement does not meet a predefined quality threshold, the at least one ground continuity measurement being a function of the at least one electrical load parameter after the circuit interrupter is in the reset state.

52. The device of claim 51, wherein the at least one electrical parameter includes a ground fault current, the grounding confirmation circuit being configured such that the at least one predefined quality threshold is substantially unaffected by the presence of the ground fault current.

53. The device of claim 51, wherein the predefined quality threshold includes a predefined impedance in the line ground conductor.

54. The device of claim 53, wherein the at least one electrical parameter includes a load current, the load sensing element being configured to increase the predefined magnitude of impedance in direct relationship to magnitude of the load current.

55. The device of claim 51, wherein the at least one signal generator includes a first signal generator that directs a first test signal into the current path, the first test signal being substantially continuous.

56. The device of claim 55, wherein the first test signal from the first generator is interrupted during a self test event.

57. The device of claim 55, wherein the at least one signal generator includes a second signal generator that directs a second test signal into the current path, the second test signal being an impulse signal of predetermined duration.

58. The device of claim 57, wherein the impulse signal has ramped edges.

59. The device of claim 57, wherein the signal from the second signal generator is derived from a DC current source.

60. The device of claim 51, wherein the at least one test signal includes a first signal portion extending for a first predetermined period of time from a substantially zero magnitude signal level to a peak magnitude signal level, the at least one test signal also including a peak signal portion extending for a second predetermined period of time, the at least one test signal also including a third signal portion extending for a third predetermined period of time from the peak magnitude signal level to the substantially zero magnitude signal level.

61. The device of claim 60, wherein the at least one signal generator is derived from a DC current source.

62. The device of claim 51, wherein the at least one signal generator includes at least one first signal generator for determining a ground continuity status in the line ground conductor and a second signal generator for determining a ground continuity status in the load ground conductor.

63. An electrical device configured to be disposed in an electrical distribution system between a source of electrical power and an electrical load, the electrical distribution system including at least one line hot conductor and a line ground conductor, the electrical load including at least one load hot conductor and a load ground conductor, the device comprising:

a power input mechanism including at least one line termination element and a line ground termination element, the at least one line termination element being configured to terminate the at least one line hot conductor, the line ground termination element being configured to terminate the line ground conductor, the power input mechanism being configured to direct electric power provided by the source of electrical power to the protective device;

a power output mechanism including at least one load termination element and a load ground termination element, the at least one load termination element being configured to terminate the at least one load hot conductor, the load ground termination element being configured to terminate the load ground conductor, the power output mechanism being configured to direct electric power provided by the source of electrical power via the power input mechanism to the electrical load;

a circuit interrupter mechanism coupled to the fault detection circuit, the circuit interrupter mechanism being configured to interrupt electrical continuity between the plurality of line termination elements and the plurality of load termination elements in a tripped state and establish electrical continuity between the plurality of line termination elements and the plurality of load termination elements in a reset state; and

a grounding confirmation circuit comprising plurality of signal generators including at least one first signal generator configured to direct at least one first test signal into a current path that includes the line ground conductor and a second signal generator configured to direct a second test signal into the current path, the grounding confirmation circuit being configured to determine a ground continuity status of the current path in accordance with a relatively low sensitivity ground continuity measurement based on the at least one first test signal or a relatively high ground continuity measurement based on the second test signal, the circuit interrupter being prevented from entering the reset state if the relatively low sensitivity ground continuity measurement or the relatively high ground continuity measurement do not meet a predefined quality threshold.

64. The device of claim 63, wherein the plurality of signal generators includes a third signal generator for determining a ground continuity status in the load ground conductor.

65. The device of claim 63, wherein the at least one first test signal is characterized by a first current magnitude and the second test signal is characterized by a second current magnitude, the second current magnitude being substantially larger than the first current magnitude.

66. The device of claim 65, wherein the at least one first test signal includes an AC signal and the second test signal includes a signal pulse.

67. The device of claim 66, wherein the at least one first test signal is characterized by a signal frequency that is substantially identical to a signal frequency of the source of electrical power.

68. The device of claim 66, wherein the at least one first test signal is characterized by a signal frequency that is substantially higher than a signal frequency of the source of electrical power.

69. The device of claim 63, wherein the at least one first test signal is characterized by a signal frequency that is substantially identical to a signal frequency of the source of electrical power.

70. The device of claim 63, wherein the at least one first test signal is characterized by a signal frequency that is substantially higher than a signal frequency of the source of electrical power.

71. The device of claim 63, wherein the second test signal is an impulse signal having a predetermined duration, the impulse signal having a rise time and a fall time that substantially eliminate frequency components greater than a predetermined frequency in the frequency domain.