Abstract: A circuit breaker having a housing, a pair of separable contacts, a current sensor strap in electrical communication with the contacts, an operating mechanism for operating the contacts, an electronic trip unit in operable communication with the sensor strap and the mechanism, and a current transformer is disclosed. The current transformer has a mixed material magnetic core having a first layer of material having a relatively high magnetic permeability, and a second layer of material having a relatively low magnetic permeability abutting the first layer of material. The core has a profile with an opening therethrough for accepting the sensor strap. A signal generator is disposed proximate the core to provide an output signal representative of a magnetic flux associated with the sensor strap. The mixed material magnetic core exhibits a dynamic range greater than a dynamic range of a similar shaped magnetic core having only one material of the first layer of material and the second layer of material.

Abstract: A circuit breaker having a housing, a pair of separable contacts, a current sensor strap in electrical communication with the contacts, an operating mechanism for operating the contacts, an electronic trip unit in operable communication with the sensor strap and the mechanism, and a current transformer is disclosed. The current transformer has a mixed material magnetic core having a first layer of material having a relatively high magnetic permeability, and a second layer of material having a relatively low magnetic permeability abutting the first layer of material. The core has a profile with an opening therethrough for accepting the sensor strap. A signal generator is disposed proximate the core to provide an output signal representative of a magnetic flux associated with the sensor strap. The mixed material magnetic core exhibits a dynamic range greater than a dynamic range of a similar shaped magnetic core having only one material of the first layer of material and the second layer of material.

Abstract: A current sensor and current transformer for monitoring electrical current is provided with a magnetic core having a mixture of magnetic materials to provide a low cost design in a compact configuration with an expanded dynamic range. The mixed material core can be fabricated either from stamped laminations or from coil stock and may include an air gap for activating a magnetic flux sensor. Multiple core configurations, including Figure-O, Figure-C, and Figure-8, having mixed material construction are disclosed and offer advantages over non-mixed material cores where dynamic range and frequency response characteristics are a consideration.

Abstract: A removable cover for a an electrical component box includes a pair of side walls having hinge edges including a hook and an engagement surface extending from the hook. The hook slides over and engages the hinge members of a box, and the engagement surface forms a sliding surface that allows rotation of the cover about the hinge elements. The hinge is easily installed and removed by orienting the cover at a selected angle relative to a longitudinal axis of the box, and lifting the hook over the hinge member to either engage or disengage the hook from the hinge members.

Abstract: The roller assembly includes: a first shaft having a longitudinal axis; a self adjusting pressure drive shaft extending parallel to the longitudinal axis, the self adjusting pressure drive shaft includes: a main body portion having a cylindrical shape; a ring surrounds the main body portion; and a flexible material is disposed between the main body portion and the ring. An apparatus for a continuously winding a transformer core in an electrical transformer includes: a feed assembly for a material, the feed assembly includes a first shaft disposed adjacent a self adjusting pressure drive shaft, the self adjusting pressure drive shaft includes: a main body portion having a cylindrical shape; a ring surrounds the main body portion; and a flexible material is disposed between the main body portion and the ring.

Abstract: A transformer includes a core having an aperture formed therein and a conductive bar extending through the core. The aperture in the core has a centroidal axis The conductive bar includes: a first surface extending generally parallel to the centroidal axis, a second surface opposite the first surface and extending generally parallel to the centroidal axis, the first surface being closer than the second surface to said centroidal axis. The conductive bar also includes means for diverting electrical current flowing through the conductive bar towards said first surface.

Abstract: Electrical distribution equipment generally includes a housing defining an enclosed space and a conductor in the enclosed space. A current transformer utilizing current in the conductor induces current in a secondary winding thereof, and a fan assembly is electrically connected to the secondary winding. The fan assembly includes a fan motor in driving relation to a fan.

Abstract: A transformer includes a core having an aperture formed therein and a conductive bar extending through the core. The aperture in the core has a centroidal axis The conductive bar includes: a first surface extending generally parallel to the centroidal axis, a second surface opposite the first surface and extending generally parallel to the centroidal axis, the first surface being closer than the second surface to said centroidal axis. The conductive bar also includes means for diverting electrical current flowing through the conductive bar towards said first surface.

Abstract: A molded case circuit breaker that includes a double headed calibration screw. The calibration screw has a first and second end with identical convex tip surfaces and screw driver engagement surfaces. The convex tip surface is suitable for engaging a bi-metal thermal overload element. The screw driver engagement surface is suitable for applying a screw driver to adjust the calibration screw position in order to adjust the deflection of the bimetal and calibrate the thermal overload protection. At least one calibration screw planar surface allows for improved sealant injection to permanently fix the screw position and associated calibration setting following adjustment.

Abstract: Electrical distribution equipment generally includes a housing defining an enclosed space and a conductor in the enclosed space. A current transformer utilizing current in the conductor induces current in a secondary winding thereof, and a fan assembly is electrically connected to the secondary winding. The fan assembly includes a fan motor in driving relation to a fan.

Abstract: A temperature sensor for use in a circuit breaker is disclosed. The temperature sensor is included in the circuit breaker and detects temperature of a target within the current path of the breaker. If the temperature of the target falls within a preselected critical range, a trip signal is triggered in a trip processor board which actuates a solenoid to trip the circuit breaker. A bridge is provided in the current path to continue normal function of the circuit breaker outside the critical range of temperatures.

Abstract: A current sensor and current transformer for monitoring electrical current is provided with a magnetic core having a mixture of magnetic materials to provide a low cost design in a compact configuration with an expanded dynamic range. The mixed material core can be fabricated either from stamped laminations or from coil stock and may include an air gap for activating a magnetic flux sensor. Multiple core configurations, including Figure-O, Figure-C, and Figure-8, having mixed material construction are disclosed and offer advantages over non-mixed material cores where dynamic range and frequency response characteristics are a consideration.

Abstract: A method permits calibration of a current sensor having a conductor that comprises at least two conductor branches electrically connected in parallel. The method comprises passing a predetermined electrical current through the conductor, measuring a fraction of the current that passes through a measured conductor branch, which is one of the two conductor branches, comparing the measured current against a predetermined target current, trimming a calibrating conductor, which is one of the at least two conductor branches, the trimming taking place when said measured current and said predetermined target current are not equal.

Abstract: A Hall effect sensor is transported to and away from a conductor to vary the sensitivity range of the sensor to current flow in the conductor. The device comprises a bracket supported on the conductor which holds a jack screw. At the lower end of the jack screw is a sensor block which holds the Hall effect sensor. The sensor block translates in a slide guide of the bracket, but is prevented from rotating. At the upper end of the jack screw is a knob for rotating the jack screw. Rotating the jack screw causes the sensor block to slide closer or farther from the conductor, which varies its sensitivity in measuring a magnetic field generated by a current in the conductor.

Abstract: A contact arm assembly is provided having an electrical contact for making and breaking an electrical current, a contact arm for supporting the electrical contact, and a bond surface on the contact arm that is conditioned for improving the bond between the electrical contact and contact arm. Also provided is an electrical circuit breaker that utilizes the improved contact arm assembly. The bond surface of the contact arm is provided with pyramid-shaped serrations that serve to more uniformly distribute the electrical current during brazing, provide multiple areas of localized current constriction during brazing, and provide collector pockets for accumulating the molten braze alloy during brazing. The uniform distribution of electrical current during brazing serves to generate a uniform temperature gradient across the braze area for uniform melting of braze alloy.

Abstract: A trip bar assembly for actuating a latching mechanism to trip a circuit breaker is disclosed. In an exemplary embodiment of the invention, the trip bar assembly comprises a trip bar having an aperture and a calibration screw. The trip bar is configured to interact with the latching mechanism and the aperture has a predetermined length. The predetermined length of the calibration screw is less than said predetermined length of said aperture such that the calibration screw is encased within the aperture prior to calibration of the trip unit. The trip bar assembly increases the calibration yield of circuit breakers by locating the calibration screws during the calibrations process.

Abstract: To allow access to a control/display module in an electronic circuit breaker, an adapter and harness are provided for remotely positioning the control/display module in a more accessible location, e.g., on the remote handle operator. An adapter plug and plate installs in place of the control/display module on the circuit breaker. The adapter plug provides connectors for a harness to extend to a mounting plate, which can be attached to the remote handle operator. The control/display module, which was removed from the circuit breaker, is installed in the mounting plate.

Abstract: A molded case circuit breaker that includes a double headed calibration screw. The calibration screw has a first and second end with identical convex tip surfaces and screw driver engagement surfaces. The convex tip surface is suitable for engaging a bi-metal thermal overload element. The screw driver engagement surface is suitable for applying a screw driver to adjust the calibration screw position in order to adjust the deflection of the bimetal and calibrate the thermal overload protection. At least one calibration screw planar surface allows for improved sealant injection to permanently fix the screw position and associated calibration setting following adjustment.

Abstract: A trip indicator for handle operator for controlling a handle of a circuit breaker comprises a cover having a window sufficiently sized to view indicia indicating a position of the handle, a trip flag having indicia indicating a TRIPPED condition, and a connection between a chuck of the handle operator and the trip flag configured to move the trip flag such that the indicia is visible through the window when the handle is in a TRIPPED position and is not visible through said window when the handle is not in the TRIPPED position.

Abstract: A molded circuit breaker cover for providing access to a calibration screw of a thermal trip unit is disclosed. The cover includes an exterior surface having an opening disposed therein and a locator extending from an underside of the cover. The locator includes a channel surface defining a channel continuous with the opening wherein the locator captures the calibration screw and aligns the calibration screw with the opening. Locator significantly increase the calibration yield of multi-pole circuit breakers by decreasing misalignment of the calibration screws during assembly of the circuit breaker.