Abstract: A circuit interrupting device comprises a conductor capable of generating heat and a temperature-activated, permanent lock out trip mechanism. The mechanism includes a plunger, a compressed or stretched spring and a fusible metal to hold the plunger. The mechanism is located near the conductor that generates heat and is configured such that when the fusible metal melts when at least one heating element is energized or a holding wire fuses when energized in response to a failed self-test the plunger is released: allowing the compressed or stretched spring to convert its potential energy into kinetic energy and moving the plunger to generate a force to unlatch a latch releasing a first spring to open a contactor switch removing power from an electrical circuit. The constant force generated by the compressed or stretched spring on the plunger inhibits the circuit interrupting device from resetting.

Abstract: A branch fault analysis system is described that identifies a source of a fault such as arc fault or ground fault event in a communicating panel. The system comprises an application running on a mobile device is configured to display a physical location and conditions experienced by each electronic circuit breaker. The system further comprises an electronic circuit breaker including trip identification means to clearly identify a branch that resulted in a breaker trip event, record and relay this information to the mobile device for an end user and one or more proximity sensors to achieve the physical location of the electronic circuit breaker in a panel. A load current, a voltage and noise levels are continuously monitored and displayed in the application with time stamps. In an event of a trip condition, the application uses conditions of the time stamps to highlight the branch that resulted in a trip.

Abstract: A circuit interrupting device with a temperature activated permanent lockout trip mechanism is provided. The temperature activated permanent lockout trip mechanism is located in close proximity to a section of conductor that generates heat. An energized first solenoid generates a magnetic force capable of moving an armature that unlatches a latch releasing a spring to open a main contactor removing power from an electrical circuit. The temperature activated permanent lockout trip mechanism upon reaching a predetermined temperature which is higher than the predetermined temperature threshold of the temperature sensing switch also generates a mechanical force capable of moving the armature that unlatches the latch releasing the spring to open the main contactor removing power from the electrical circuit.

Abstract: A circuit interrupting device with a temperature activated permanent lockout trip mechanism is provided. The temperature activated permanent lockout trip mechanism is located in close proximity to a section of conductor that generates heat. An energized first solenoid generates a magnetic force capable of moving an armature that unlatches a latch releasing a spring to open a main contactor removing power from an electrical circuit. The temperature activated permanent lockout trip mechanism upon reaching a predetermined temperature which is higher than the predetermined temperature threshold of the temperature sensing switch also generates a mechanical force capable of moving the armature that unlatches the latch releasing the spring to open the main contactor removing power from the electrical circuit.

Abstract: A residential circuit breaker is provided with means to visually identify certain status information about the device such as detection of a condition through a label. The residential circuit breaker comprises an electronic pole housing that includes an opening for a light emitting diode (LED) light to pass through. The residential circuit breaker comprises the label located on a front of the residential circuit breaker such that the label is used to identify device information about the residential circuit breaker. The label includes a window in a specified area for the LED light to shine through the label to provide an arc fault circuit interrupter (AFCI)/a ground-fault circuit interrupter (GFCI) indication. The residential circuit breaker further comprises a LED mounted on a printed circuit board (PCB) assembly to transmit the light from the LED to an external surface of the circuit breaker without the need of a translucent plastic part.

Abstract: A circuit breaker includes a first electrical contact and a second electrical contact moveable between an open state and a closed state; an armature, wherein movement of the armature from a first position to a second position initiates the first electrical contact and the second electrical contact to move from the closed state to the open state; a first electromagnetic device configured to move the armature from the first position to the second position in response to being energized by a first signal; and a second electromagnetic device configured to move the armature from the first position to the second position in response to being energized by a second signal and in response to generation of the first signal and the first electrical contact and the second electrical contact still being in the closed state. Other circuit breakers and methods of operating circuit breakers are disclosed.

Abstract: A lockout subassembly of an electronic circuit breaker. The lockout subassembly includes a rotatable latch bar having an engagement portion configured to engage with and prevent movement of an operating handle to an ON position, the rotatable latch bar including a lock portion, and a latch device configured to be receivable in the lock portion, wherein rotation of the rotatable latch bar is limited between a first and second rotational position in response to the latch device being received in the lock portion. The lockout of the operating handle can be removed upon passing at least one test so that the operating handle can be moved to the ON position. Circuit breakers including the lockout subassembly and methods of operating the circuit breaker are provided, as are other aspects.

Abstract: A smart residential circuit breaker includes a hybrid assembly that incorporates a solid-state circuit element integrated into a simplified mechanical pole having main contacts. The solid-state circuit element includes a printed circuit board (PCB) with a micro SD reader to provide faster opening speeds. The smart residential circuit breaker is configured for use for different current levels and controlled by the PCB. The smart residential circuit breaker includes a mag-latch. The PCB is configured to send a signal to the mag-latch to open and close the main contacts within microseconds of detecting an over-current.

Abstract: A residential circuit breaker is provided with means for showing proper installation of a panel wire to ensure that an installer/a contractor is aware that the panel wire has been fully inserted into a circuit breaker lug. The residential circuit breaker comprises a circuit breaker lug having a lug body and a lug body screw. The residential circuit breaker further comprises a panel wire install indicator to indicate proper insertion of a panel wire in the lug body by providing a visual indication to an installer/contractor that the panel wire has been fully inserted in the circuit breaker lug during and after installation. The panel wire install indicator includes a panel wire indicator lever wherein the panel wire indicator lever can indicate if the panel wire has been installed properly and wherein there is a visual indication if the panel wire is no longer present in the lug body.

Abstract: A multi-pole circuit breaker such as a residential electronic circuit breaker is provided. It includes a means to prevent a breaker mechanism from latching, i.e., a breaker armature from latching with a cradle if certain criterion is met. In particular, the multi-pole circuit breaker comprises a breaker mechanism including a breaker armature, a cradle and an armature latch bar to prevent the breaker armature from latching with the cradle. The armature latch bar includes a recessed feature that interfaces with the breaker armature, an armature latching surface that needs to be removed before the breaker mechanism can be latched and an armature latching lever that prevents a rotation of the breaker armature.

Abstract: A circuit breaker includes a first electrical contact and a second electrical contact moveable between an open state and a closed state; an armature, wherein movement of the armature from a first position to a second position initiates the first electrical contact and the second electrical contact to move from the closed state to the open state; a first electromagnetic device configured to move the armature from the first position to the second position in response to being energized by a first signal; and a second electromagnetic device configured to move the armature from the first position to the second position in response to being energized by a second signal and in response to generation of the first signal and the first electrical contact and the second electrical contact still being in the closed state. Other circuit breakers and methods of operating circuit breakers are disclosed.

Abstract: A smart residential circuit breaker includes a hybrid assembly that incorporates a solid-state circuit element integrated into a simplified mechanical pole having main contacts. The solid-state circuit element includes a printed circuit board (PCB) with a micro SD reader to provide faster opening speeds. The smart residential circuit breaker is configured for use for different current levels and controlled by the PCB. The smart residential circuit breaker includes a mag-latch. The PCB is configured to send a signal to the mag-latch to open and close the main contacts within microseconds of detecting an over-current.

Abstract: A multi-pole circuit breaker such as a residential electronic circuit breaker is provided. It includes a means to prevent a breaker mechanism from latching, i.e., a breaker armature from latching with a cradle if certain criterion is met. In particular, the multi-pole circuit breaker comprises a breaker mechanism including a breaker armature, a cradle and an armature latch bar to prevent the breaker armature from latching with the cradle. The armature latch bar includes a recessed feature that interfaces with the breaker armature, an armature latching surface that needs to be removed before the breaker mechanism can be latched and an armature latching lever that prevents a rotation of the breaker armature.

Abstract: A lockout subassembly of an electronic circuit breaker. The lockout subassembly includes a rotatable latch bar having an engagement portion configured to engage with and prevent movement of an operating handle to an ON position, the rotatable latch bar including a lock portion, and a latch device configured to be receivable in the lock portion, wherein rotation of the rotatable latch bar is limited between a first and second rotational position in response to the latch device being received in the lock portion. The lockout of the operating handle can be removed upon passing at least one test so that the operating handle can be moved to the ON position. Circuit breakers including the lockout subassembly and methods of operating the circuit breaker are provided, as are other aspects.

Abstract: A circuit breaker neutral connector assembly is provided. Circuit breaker neutral connector assembly includes a neutral connector including a first side configured to make electrical connection with a neutral bar, a shield of an insulating material abutting a second side of the neutral connector opposite the first side, and a bias spring abutting the shield and configured to bias the neutral connector relative to a circuit breaker housing. Electronic circuit breakers including a circuit breaker neutral connector assembly and methods of making neutral connections are provided, as are other aspects.

Abstract: An apparatus and a method are provided to reduce arcing between a circuit breaker having a breaker line terminal and a panel board terminal of an electrical panel board during installation and/or removal. The apparatus has an auto tripping mechanism including an auto trip lever having an end and a spring disposed at or near the end of the auto trip lever. The auto trip lever is configured to interface with an armature in a module one that houses a cradle of a breaker mechanism. The breaker mechanism is prevented from latching until the circuit breaker has been installed in the electrical panel board by keeping a breaker handle in a tripped position when the breaker line terminal and the panel board terminal are connected. The spring is configured to force the auto trip lever to rotate for providing a force and a deflection to automatically trip the circuit breaker as the circuit breaker is being removed from the electrical panel board and before the breaker line terminal and the panel board terminal separate.

Abstract: An apparatus and a method are provided to block and unblock a breaker handle of a circuit breaker having main contacts. The apparatus comprises a locking mechanism including a locking handle shaft and a locking latch. The locking handle shaft is configured to latch the locking mechanism for keeping the breaker handle in a mid-position in which the main contacts stay open. The locking handle shaft has a latching surface configured to be removed from its position in order to rotate the breaker handle to a fully ON position in which the main contacts fully close. The locking latch is configured to prevent rotation of the locking handle shaft. The locking latch is configured to engage and disengage with the locking handle shaft in order to rotate the breaker handle from a reset position to the mid-position in which the locking mechanism locks the breaker handle rotation thus preventing the main contacts from closing.

Abstract: A circuit breaker including an adjustable instantaneous trip level. Adjustable instantaneous trip level can be applied to a one-pole and/or two-pole circuit breakers including a thermal and magnetic mechanism, including AFCI, CAFCI, and/or GFCI constructions. The circuit breaker includes a magnet position adjustment mechanism allowing an operator to adjust the instantaneous trip level to a desired setting, such as between about 5 to 10 times the handle rating. The design also allows for alternate magnets to be used for either an increased or decreased instantaneous settings as desired. In two-pole circuit breakers, the instantaneous trip level can be set independently for each mechanism pole. Multi-pole circuit breakers and methods of adjusting instantaneous trip level are provided, as are other aspects.

Abstract: A circuit breaker neutral connector assembly is provided. Circuit breaker neutral connector assembly includes a neutral connector including a first side configured to make electrical connection with a neutral bar, a shield of an insulating material abutting a second side of the neutral connector opposite the first side, and a bias spring abutting the shield and configured to bias the neutral connector relative to a circuit breaker housing. Electronic circuit breakers including a circuit breaker neutral connector assembly and methods of making neutral connections are provided, as are other aspects.

Abstract: A two-pole circuit breaker is provided that includes a first mechanical pole, a second mechanical pole and an electronic pole. The first mechanical pole includes a first armature having a first armature extension, and the second mechanical pole includes a second armature having a second armature extension. The electronic pole includes a first solenoid and a second solenoid, the first armature extension is disposed adjacent the first solenoid, and the second armature is disposed adjacent the second solenoid. Numerous other aspects are provided.