Abstract: Systems and methods for auto-monitoring a trip solenoid and a switching semiconductor in a circuit breaker comprises determining whether the trip solenoid or the switching semiconductor is open-circuited or otherwise non-operational. The trip solenoid has multiple windings therein and the switching semiconductor has multiple semiconductor switches therein. The circuit breaker automatically performs a designated action if one of the multiple windings or one of the semiconductor switches is determined to be open-circuited or otherwise non-operational. In some embodiments, the circuit breaker is a miniature circuit breaker.

Abstract: A trip assembly for a circuit breaker includes a trip lever and a trip actuator. The trip lever causes electrical contacts, which are in a closed position, to disengage from each other into an open position and interrupt current flow to a circuit, when tripped by the trip actuator due to an overcurrent condition. The trip actuator includes a bimetallic member, a yoke and an armature with an opening in which an end of the trip lever is latched in the closed position. The yoke includes a tab adjacent to the opening. When the trip lever is latched in the opening, the end of the trip lever includes first, second and third surfaces that contact a front surface of the armature, an interior surface of the armature defining the opening, and the tab of the yoke, respectively, to provide a consistent magnetic gap between the back side of the armature and the yoke.

Abstract: A layered mechanism for use in a circuit breaker fabricated by automated assembly operations includes a movable electrical contact mounted on a blade for movement relative to a stationary electrical contact. The major portion of the blade is substantially flat, and a handle is coupled to the blade to move said blade. A toggle spring is connected to the blade to apply a biasing force in the plane of the flat portion of the blade. The handle and blade form cooperating opposed surfaces that allow engagement of the handle with the blade so that movement of the handle can move the blade while allowing pivoting movement of the blade relative to the handle, while opposed surfaces resist upward pivoting movement of the blade when the toggle spring is attached to the blade during assembly of the circuit breaker.

Abstract: A trip unit in a miniature circuit breaker having a plurality of stacked bimetal elements welded front-to-back at one end and attached to a load terminal. The bimetal elements are made of similar compositions and have the same thickness. The free ends are connected to a yoke and to a pigtail that is optionally wound around the yoke in which the bimetals are received. The pigtail is connected to the conductive blade of the trip unit. To attach the pigtail from one direction, a notch is formed in the free end of one of the bimetals, exposing part of the other bimetal behind it. Or, two notches are formed in a staggered relationship such that the pigtail connections can be made from either direction. The stacked relationship of the bimetal elements allows the overall width of the circuit breaker to be reduced without sacrificing its rating requirements with one bimetal.

Abstract: A trip unit in a miniature circuit breaker includes a magnetic yoke and a bimetal mounted on the outside of the yoke. The bimetal is welded at one end to a load terminal that leads to a terminal connector and at the other end to a pigtail. The pigtail, instead of the bimetal, passes through the yoke for connection to the blade of the circuit breaker. To induce a higher magnetic field for faster tripping, a second pigtail may be passed through the yoke in which one end of the second pigtail is connected to the load terminal near the terminal connector and the other end is connected to the bimetal near the load terminal connection point. The load terminal may include at least two parts, one part including the adjustment screw and the other part including the terminal screw. These parts may be separated by air or an insulator.

Abstract: A trip unit in a miniature circuit breaker includes a magnetic yoke and a bimetal mounted on the outside of the yoke. The bimetal is welded at one end to a load terminal that leads to a terminal connector and at the other end to a pigtail. The pigtail, instead of the bimetal, passes through the yoke for connection to the blade of the circuit breaker. To induce a higher magnetic field for faster tripping, a second pigtail may be passed through the yoke in which one end of the second pigtail is connected to the load terminal near the terminal connector and the other end is connected to the bimetal near the load terminal connection point. The load terminal may include at least two parts, one part including the adjustment screw and the other part including the terminal screw. These parts may be separated by air or an insulator.

Abstract: A trip unit in a miniature circuit breaker having a plurality of stacked bimetal elements welded front-to-back at one end and attached to a load terminal. The bimetal elements are made of similar compositions and have the same thickness. The free ends are connected to a yoke and to a pigtail that is optionally wound around the yoke in which the bimetals are received. The pigtail is connected to the conductive blade of the trip unit. To attach the pigtail from one direction, a notch is formed in the free end of one of the bimetals, exposing part of the other bimetal behind it. Or, two notches are formed in a staggered relationship such that the pigtail connections can be made from either direction. The stacked relationship of the bimetal elements allows the overall width of the circuit breaker to be reduced without sacrificing its rating requirements with one bimetal.

Abstract: A layered mechanism for use in a circuit breaker fabricated by automated assembly operations includes a movable electrical contact mounted on a blade for movement relative to a stationary electrical contact. The major portion of the blade is substantially flat, and a handle is coupled to the blade to move said blade. A toggle spring is connected to the blade to apply a biasing force in the plane of the flat portion of the blade. The handle and blade form cooperating opposed surfaces that allow engagement of the handle with the blade so that movement of the handle can move the blade while allowing pivoting movement of the blade relative to the handle, while opposed surfaces resist upward pivoting movement of the blade when the toggle spring is attached to the blade during assembly of the circuit breaker.

Abstract: An arrangement for reducing pressure inside a circuit breaker caused by gas produced during an electrical interruption event, including a base, an interrupter assembly, and a trip unit base. A structure having a surface is positioned in the base at an angle relative to a vent opening of the interrupter assembly. The trip unit base includes a complementary structure opposing the structure to form a cavity. The base includes a chamber area adjacent to an opening of a vent chute that leads away from the circuit breaker. During an electrical interruption event, hot explosive gas, carbon, and molten metal debris are directed away from the vent opening of the interrupter assembly along the angled surface of the structure and toward the opening of the vent chute. In this manner, pressure in the circuit breaker is reduced during an electrical interruption event, and undesirable buildup of debris is reduced.

Abstract: The present invention provides an apparatus for use in arcing fault detection systems within circuit breakers and which is adapted for automated production by top-down assembly. In one embodiment, the apparatus includes a circuit board and a two-piece sensing coil within a two piece housing with its center oriented horizontally relative to the circuit board. In other embodiments the sensing coil is one-piece and is either preassembled with a sensing bus and oriented horizontally or oriented vertically relative to the circuit board. The invention also includes several methods for making electrical connections to the circuit breakers.

Abstract: An apparatus for use in arcing fault detection systems within circuit breakers and which is adapted for automated production by top-down assembly. The invention also includes several devices for making electrical connections to the circuit breakers, including a lug having a top and a hollow center, the top having a hole connecting the top to the hollow center for accessing a wirebinding screw, a neutral bus having a first end and a second end, the first end disposed within the hollow center beneath the hole, a wire binding screw disposed in the hole and extending through the hollow center for securing a first wire to the first end of the neutral bus, and a strain relief member connected to the second end of the neutral bus for securing a second wire connected to the second end of the neutral bus.

Abstract: An apparatus for use in arcing fault detection systems within circuit breakers and which is adapted for automated production by top-down assembly. In one embodiment, the apparatus includes a circuit board and a two-piece sensing coil within a two piece housing with its center oriented horizontally relative to the circuit board. In other embodiments the sensing coil is one-piece and is either preassembled with a sensing bus and oriented horizontally or oriented vertically relative to the circuit board. Also included are several methods for making electrical connections to the circuit breakers.

Abstract: The present invention provides an assembly and method for mounting a plurality of circuit breakers for electrical and mechanical connection to a bus bar in a module of a distribution board. The mounting assembly includes each circuit breaker having a housing which is defined by a contact end for connecting to the bus bar, a mounting end for securing to the cell of the distribution board, and side panels extending therebetween. Each housing has a top surface and a bottom surface. The connect end of each housing has a bus bar terminal for connecting to the bus bar. At least one spacer is located between at least two of the circuit breakers. The spacer has a predetermined width between the side panels of adjacent circuit breakers. The spacer width is sufficient to spread the circuit breakers apart from each other and align the bus bar terminal of each housing with the busbar.

Abstract: A remotely controllable circuit breaker device for interrupting current in a circuit path between a source and a load includes local and remote monitoring capabilities and a gear mechanism for reliable remote control of the interruption mechanism. The device includes a first contact and a second contact cooperatively arranged in the circuit path so as to provide current from the source to the load. At least one of the contacts is disposed on a contact carrier which is movable for interrupting the current provided to the load. The gear mechanism includes a motor with a rotatable shaft which responds to open and closed control signals generated from a remote location, and a gear, rotatably responsive to the rotatable shaft, for controlling the contact carrier so that the circuit path is interrupted and established, respectively. The gear mechanism controls the contact carrier using a coupling arrangement, which has a first part coupled to the contact carrier and a second part coupled to the gear.

Abstract: A coupling member for securing a spring to a rotatable motor shaft so that the spring rotates with the motor shaft. The coupler has a cylindrical hollow middle which fits snugly onto the motor shaft and includes a main body portion having a smaller cylindrically shaped nose portion extending therefrom for receiving one end of the spring therearound. The main body portion includes a ramp portion, extending upwardly therefrom, a wall behind the ramp portion and a slot therein for receiving a hook portion extending from the spring. The hook portion is snugly secured in the slot and behind the wall so that as the motor shaft rotates, the coupler member causes the spring to rotate with the motor shaft.

Abstract: A circuit breaker device for interrupting current in a circuit path between a source and a load includes a first contact and a second contact cooperatively arranged in the circuit path so as to provide current from a source to a load. A trip mechanism assembly, which includes an armature, a bimetal and a yoke, is provided for interrupting the current. The armature includes an aperture in which a latch point is provided to engage a latching surface of a trip lever for latching the trip lever thereon. The amount of current that is required to cause the trip mechanism to interrupt the circuit path is determined by the amount of overlap between the latching surface and the latch point. This overlap is adjusted by bending a calibration plate by tightening a calibration screw which extends through an aperture in a circuit breaker housing and a slotted aperture in the calibration plate. A substantially square shaped nut secures the calibration screw tightly against the housing.

Abstract: The present invention provides a circuit breaker having a terminal nut retainer 10 for securely holding a nut 65 in a fixed position adjacent and below a circuit breaker terminal 60. The circuit breaker is placed in a circuit by securing a source electrical connector to a source terminal and/or a load electrical connector to a load terminal. A screw 61 is used to fasten the electrical connector 67 to its respective terminal 60. The nut 65 for the screw 61 is held in a fixed position by the terminal nut retainer 10. The terminal nut retainer 10 has a nut retaining cavity 14 defined by walls which hold the nut 65 and keep it from turning while the screw 61 is tightened to establish a tight electrical connection between the connector 67 and the terminal 60. The terminal nut retainer 10 is held in position by a sliding and locking engagement between projections 30 and 34, respectively, on the terminal nut retainer 10 and slots 52 and 54, respectively, in the circuit breaker casing.