Abstract:
A surge protection system provides surge protection to one or more circuits. Each circuit is connected to power and a surge protection module bridges the circuit such that the surge protection module absorbs surges from the power and/or the circuit. Being that, after exposure to certain amounts of surges, the surge protection modules lose effectiveness for surge protection, each surge protection module is independently removable and replaceable by a user without risk of personal injury from shock caused by making personal contact with the power and/or circuit. In some embodiments, a filter circuit is provided to filter out noise on the circuit. It is anticipated that the protection module includes indicators to inform a user that the protection circuit is operational and whether protection has been lost. Further, in some embodiments, a fuse is provided to protect the circuit from over current.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. provisional application No. 62/466,688 filed on Mar. 3, 2017, the disclosure of which is incorporated by reference. 
    
    
     FIELD 
     This invention relates to the field of electrical surge protection and more particularly to a system for providing surge protection to one or more circuits in a modular fashion. 
     BACKGROUND 
     There are many situations in which surge protection is desired to protect equipment from electrical surges caused by nature or power-line fluctuations. Electronic surge protection components known in the industry include, for example, metal-oxide varistors, arc gaps, gas discharge tubes, etc. 
     As the known electronic surge protection components are exposed to power-line surges, the electronic surge protection components absorb much of the energy of the surge, limiting the amount of surge energy getting to other equipment on the power line(s). Each time the electronic surge protection components absorb such energy, the life of such electronic surge protection components decreases, until, eventually there is little surge protection capability remaining, at which time, the power-line circuit that was protected by that surge protection components is no longer protected. 
     Often, several surge protectors are deployed to protect individual circuits of an electrical wiring system. Take for example, a gas station arrangement having a car wash, lighting, several dispensing bays, car vacuum systems, an air compressor, inside-store register systems, inside lighting, refrigeration, etc. It is important to have each individual circuit of such an arrangement individually protected so if the power grid experiences a surge, the surge from the power grid is mitigated before reaching the devices on each protected circuit and so that if one of the devices (e.g., the outdoor lighting) on the protected circuit experiences a surge, the surge is mitigated before reaching devices on other circuits. 
     In the past, surge protection systems offered multiple circuit protection, but as discussed above, as surges occur in one or several circuits, the entire surge protection system need be replaced or repaired, requiring removal by an experienced electrician. During the time when such surge protection systems are being repaired/replaced, each circuit protected by these surge protection systems go without power until the surge protection system is replaced, which is not desired as many such applications require 24-hour operation and shutting down several circuits to replace a multi-circuit surge protection system often requires closing the entire operation (e.g., lack of lighting is not acceptable for safety reasons, etc.). 
     What is needed is a system that will provide for individual replacement of surge protection for individual circuits without the need of an electrician. 
     SUMMARY 
     A surge protection system provides surge protection to one or more circuits. Each circuit is connected to power and a surge protection module bridges the circuit such that the surge protection module absorbs surges from the power and/or the circuit. Being that, after exposure to certain amounts of surges, the surge protection modules lose effectiveness for surge protection, each surge protection module is independently removable and replaceable by a user without risk of personal injury from shock caused by making personal contact with the power and/or circuit. In some embodiments, a filter circuit is provided to filter out noise on the circuit. It is anticipated that the protection module includes one or more indicators to inform a user that the protection circuit is operational and whether protection has been lost. Further, in some embodiments, a fuse is provided to protect the circuit from over current. 
     In one embodiment, a surge protection system is disclosed including a main board having a first connector for connecting to input power, a second connector for connecting to a circuit, an electrical connection between the first connector and the second connector, and a protection module safety connector bridging the electrical connection. The protection module safety connector has recessed contacts for protection from electric shock. A surge protection module is removably connected to the protection module safety connector. The surge protection module has at least one component connected to the electrical connection through the protection module safety connector. The input power, power to the circuit, and the recessed contacts are not exposed to human touch. 
     In another embodiment, a surge protection system is disclosed including a main board having a first connector for connecting to input power, a second connector for connecting to a circuit, an electrical connection between the first connector and the second connector, and a protection module safety connector bridging the electrical connection, The protection module safety connector having recessed contacts for protection from electric shock. A surge protection module is connected to the protection module safety connector. The surge protection module has a first metal oxide varistor connected between a line potential of the electrical circuit and a neutral potential of the electrical circuit and a second metal oxide varistor connected between a line potential of the electrical circuit and earth ground potential of the electrical circuit such. The input power or power to the circuit is not exposed for human touch. 
     In another embodiment, a method of protecting a circuit includes connecting the circuit to a surge protection system and connecting the surge protection system to a source of power. The surge protection system electrically connects the circuit to the source of power. A protection module is connected (e.g. plugged) to a protection module safety connector of the surge protection system. The protection module has components for protecting the circuit and source of power from power line surges. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which: 
         FIG. 1  illustrates a plan view of a surge protection system of the present invention. 
         FIG. 2  illustrates a plan view of a connection block of the surge protection system. 
         FIG. 3  illustrates a plan view of a second connection block of the surge protection system. 
         FIG. 4  illustrates a cut-away elevation view of the surge protection system. 
         FIG. 5  illustrates an elevation view of a protection module safety connector of the surge protection system. 
         FIG. 6  illustrates a perspective view of the surge protection system with a single surge protection module installed. 
         FIG. 7  illustrates a plan view of a panel of one of the surge protection modules. 
         FIG. 8  illustrates a schematic diagram of the main circuit board of the surge protection system. 
         FIG. 9  illustrates a schematic diagram of the surge protection module of the surge protection system. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures. 
     Throughout this description, the term circuit is used to describe a power-distribution circuit to one or more devices. For example, in the United States, this is typically a 120 VAC or 240 VAC, 60 Hz circuit, but there is no limitation on the voltage, AC or DC, frequency, etc., as other countries and/or applications operate on different voltages and frequencies. 
     Throughout this description, the term “electrician” is used to describe a technician that is trained and/or licensed to work around live electrical circuits. For example, a gas-station owner is not typically an “electrician,” and, therefore, would not be qualified to take on the task of replacing a surge protection device of prior, as there is often danger in disconnecting and reconnecting of the live wires of the circuit, etc. 
     Throughout this description, for example purposes, a twelve-circuit protection system is described, though it is fully anticipated that any number of circuits be protected from one circuit to many circuits, as needed and practical. 
     Referring to  FIG. 1 , a plan view of a surge protection system  8  of the present invention is shown. The surge protection system  8  includes one or more surge protection modules  40  that are replaceable, each containing the active surge protection components for protecting a circuit from surges. The surge protection system  8  has a series of connection blocks  12 / 14  for connecting to power (e.g. power from the main line) and for connecting to each circuit. The connection blocks  12 / 14  are wired such that the surge protection system  8  is easily installed with exchangeability between power inputs on one side and circuit connections on the other and vice versa. In this, as shown in detail in  FIGS. 2 and 3 , there is a neutral connection  12 N/ 14 N, a ground connection  12 G/ 14 G, a first hot connection  12 H 1 / 14 H 1 , and a second hot connection  12 H 2 . 14 H 2  on each connection block  12 / 14 . In this way, the power line in is connected to the first hot connection  12 H 1 / 14 H 1  and the power to the circuit is connected to the second hot connection  12 H 2 / 14 H 2 , providing an easy way to configure the surge protection system  8  with inputs/outputs on either side, as desired. 
     As with most protection devices, a fuse  20  is provided in each circuit to limit current to the circuit being protected. It is fully anticipated that in some embodiments, no fuse  20  is present, though it is highly desired to have fuses  20 . 
     Also, optional filter circuits  22  are provided to filter out noise on each circuit. Note that, although the filter circuits  22  are anticipated to be located on the main board  10  or within the surge protection modules  40 , it is anticipated that the filter circuits  22  be on the main board  10 , since the filter circuits  22  do not degrade as surges occur. 
     As discussed above, it is a goal to provide replaceability of surge protection modules  40  that have failed without the need of excessive down-time, and without the need of an electrician. To this, the surge protection system  8  is housed within, for example, an enclosure  6  (see  FIG. 4 ) and all high-voltage points (e.g. fuses  20  and connection blocks  12 / 14  are covered/insulated from exposure by an insulating material  11  so that whoever changes the surge protection modules  40  has little chance of electrocution. Further, as will be shown in  FIGS. 5 and 6 , the protection module safety connector  25  for connecting the surge protection modules  40  to the main board  10  has recessed conductors  26 N/ 26 H/ 30 G/ 32 S to shield the user from dangerous voltages. Therefore, removal of the surge protection module  40  does not interrupt power provided to the protected circuit. 
     Referring to  FIGS. 2 and 3 , detailed plan views of connection blocks  12 / 14  of the surge protection system  8  is shown. The connection blocks  12 / 14  are wired such that the surge protection system  8  is easily installed with exchangeability between power input connected to the first connection block  12  and output circuits connected to the second connection block  14  or, alternatively, power input connected to the second connection block  14  and output circuits connected to the first connection block  12 . In this, there is a neutral connection  12 N/ 14 N, a ground connection  12 G/ 14 G, a first hot connection  12 H 1 / 14 H 1 , and a second hot connection  12 H 2 . 14 H 2  on each connection block  12 / 14 . In this way, the power line in is connected to the first hot connection  12 H 1 / 14 H 1  and the power to the circuit is connected to the second hot connection  12 H 2 / 14 H 2 , providing an easy way to configure the surge protection system  8  with inputs/outputs on either side, as desired. 
     Referring to  FIG. 4 , a cut-away elevation view of the surge protection system  8  is shown. Although any suitable enclosure is anticipated, in this example, the main board  10  is held within an enclosure  6  (typically a metal enclosure) that has a cover  7  that is attached to the enclosure  6 , for example by a hinge  5 . Note that the cover  7  is made of any material, though a translucent or transparent material is anticipated to provide a quick view of the indicators  42 / 44 / 46 / 48  of the surge protection modules  40  for quick identification of which surge protection module  40  that has failed. In  FIG. 4 , the filter circuits  22  are shown mounted to the main board  10  and the fuses  20  sit in fuse clips  21  for quick replacement (e.g., by an electrician). 
     The surge protection modules  40  have internal connectors that receive the respective protection module safety connectors  25 , one of which is shown in detail in  FIG. 5 . Each protection module safety connector  25  is shown having a leg for a hot connection  26 , a leg for a neutral connection  28 , a leg for a ground connection  30 , and a leg for a signaling connection  32  (e.g. to signal status to a remote location). The number of conductors within the protection module safety connector  25  in this example is four, though in other embodiments, two, three, or more conductors is anticipated. 
     Referring to  FIG. 5 , an elevation view of a protection module safety connector  25  of the surge protection system  8  is shown. Each protection module safety connector  25  is shown having a leg for a hot connection  26 , a leg for a neutral connection  28 , a leg for a ground connection  30 , and a leg for a signaling connection  32  (e.g. to signal status to a remote location). The number of conductors  26 H/ 28 N/ 30 G/ 32 S within the protection module safety connector  25  in this example is four, though in other embodiments, two, three, or more conductors is anticipated. Note that each of the conductors  26 H/ 28 N/ 30 G/ 32 S are recessed within the respective leg (leg for a hot connection  26 , a leg for a neutral connection  28 , a leg for a ground connection  30 , and a leg for a signaling connection  32 ) to protect from inadvertent contact by a user replacing a surge protection module  40  with potentially dangerous power levels. This recessed contact operates in a similar fashion to standard power outlets in one&#39;s home. 
     Referring to  FIG. 6 , a perspective view of the surge protection system  8  with a single surge protection module  40  installed is shown. The main board  10  is shown out of the enclosure  6  and the single surge protection module  40  is installed onto the protection module safety connector  25 . Also visible are the connection blocks  12 / 14  and the fuses  20 . 
     Referring to  FIG. 7 , a plan view of an indicator panel of one of the surge protection modules  40  is shown. So that the user (e.g. shop keeper, station owner, etc.) knows that each circuit is protected and the status of each surge protection module  40 , one or more indicators  42 / 44 / 46 / 48  are provided on the face of each surge protection module  40 . 
     After a surge protection system  8  is exposed to one or more surges, it is anticipated that one or more of the surge protection modules  40  weaken or fail. Such weakening or failure is detected by circuitry within each surge protection module  40  and indicated on the one or more indicators  42 / 44 / 46 / 48  and/or communicated electronically to a remote system through the signal connection  32 S. By making the surge protection modules  40  replaceable by those other than an electrician, a user (for example, a shop owner, gas station manager, etc.) seeing an indicator  42 / 44 / 46 / 48  that indicates loss of surge protection is able to remove a surge protection module  40  that has failed and replace that surge protection module  40  with a new surge protection module  40 . In this way, the user is able to order spare surge protection modules  40  or, upon detecting a failure, the user is able to order a new surge protection module  40  from the manufacturer (e.g., for overnight shipping, etc.). 
     Referring to  FIG. 8 , a schematic diagram of the main board  10  of the surge protection system  8  is shown. In the exemplary wiring scheme shown, each connection block  12 / 14  has two hot connections, hot- 1   50  and hot- 2   52 . For example, the input power hot is connected to hot- 2   52  on either connection block  12 / 14  and the output power hot is connected to the hot- 1   50  on the other connection block  12 / 14 , allowing for interchangeable wiring from either side of the main board  10 . The neutral  54  and ground  56  are connected to respective neutral and ground connections of each connection block  12 / 14 . The fuse  20  protects the filter circuit  22  and the surge protection module  40  (not shown in  FIG. 8 ), and the protected circuit from excessive current. I some embodiments, optic reflector sensors  74  are used to detect the presence of each surge protection module  40  and interface to a dry-contact signaling system  72  (as known in the industry) for reporting missing/failed surge protection modules  40  to a remote site. 
     Referring to  FIG. 9 , a schematic diagram of the surge protection module  40  of the surge protection system  8  is shown. The surge protection module  40  has a connector  80  that mates with one of the protection module safety connectors  25 . The connector has a first contact  86 H for mating with the first recessed connector  26 H of the main board for connecting to the line (or “hot”) of the circuit that is being protected from surges. The connector has a second contact  88 N for mating with the second recessed connector  28 N of the main board for connecting to the neutral of the circuit that is being protected from surges. The connector has a third contact  90 G for mating with the third recessed connector  30 G of the main board for connecting to the ground of the circuit that is being protected from surges. In some embodiments, the connector has a fourth contact  92 S for mating with the fourth recessed connector  32 S of the main board for relaying signaling information to a remote location. 
     Although many configurations, layouts, and implementations of a surge protection module  40  are anticipated, the exemplary schematic shown in  FIG. 9  includes two metal-oxide varistors (MOVS)  47 / 49  with a first metal-oxide varistors (MOVS)  47  bridging the line and neutral and a second metal-oxide varistors (MOVS)  49  bridging the line and ground (e.g. earth ground). Again, this is an example, and other embodiments are fully anticipated, for example, a single metal-oxide varistors (MOVS)  47  bridging the line and neutral, etc. 
     In this embodiment, a transient voltage suppression diode  51  also bridges the line and neutral, providing added protection from transient voltage spikes. 
     As the metal-oxide varistors (MOVS)  47 / 49  absorb energy from circuit surges, the metal-oxide varistors (MOVS)  47 / 49  weaken and, eventually, fail in an open mode—e.g. they no longer function to absorb substantial amounts of energy of a circuit surge. In some embodiments, the metal-oxide varistors (MOVS)  47 / 49  include signaling outputs that drive two indicators  42 / 48 . The “Replace” indicator  48  illuminates when the metal-oxide varistors (MOVS)  47 / 49  indicate they can no longer absorb energy from surges while the “Good” indicator  42  illuminates when the metal-oxide varistors (MOVS)  47 / 49  indicate they are in good condition. 
     In some embodiments, a “Grounded” indicator  44  illuminates when proper grounding to earth is present and, in some embodiments, an “Energize” indicator  44  illuminates when power is present in the protected circuit. 
     Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result. 
     It is believed that the system and method as described and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.