ADD-ON GROUND FAULT MODULE

Abstract: Ground fault detectors commonly interconnect secondary windings of the phase current transformers of a source (N1, N2, N3) into a summing circuit. This circuit will produce a zero output when there is no ground fault condition and will produce on a non-zero output if a ground fault condition exists. A problem exists in that a ground fault detector is not easily connected to an existing system. A solution to this problem is an add-on ground fault system including a module (10) readily connected to the distribution line (N4, N5, N6) and to the associated breaker (STS).

Description: 15 20 ADD-ON GROUND FAULT MODULE DESCRIPTION 25 Technical Field The present invention relates generally to overcurrent protection devices and, more particularly, to a ground fault 30 module that is particularly adapted for connection to a circuit breaker which is automatically tripped when a ground fault current is detected. 35 SUBSTITUTE SHEET Background Prior Art Ground fault conditions result in an imbalance or inequality in currents flowing from a source to and from a load. One manner 5 of detecting this imbalance in the past has been to utilize a transformer having an opening or n window π through which the conductors of the circuit are passed with a relay connected to the transformer that is activated to interrupt 10 the circuit whenever a ground fault condition occurs. Various alternate types of approaches of detecting ground faults have been proposed, including the interconnection of the secondaxy 15 windings of the phase current transformers into a summing circuit which will result in a zero output when there is no ground fault condition present." However, if the summation of the secondary circuits is not zero, a ground fault 20 condition exists and various solid state circuitry has been proposed for utilizating the ground fault condition as a tripping signal for relay activated circuit breakers. Industrial circuit breakers which 25 respond to overcurrent conditions ranging from overload to short-circui are common and have many applications. Many of these devices also incorporate sensing devices to sense a ground fault condition and to activate the circuit 30 breaker when such ground fault conditions occur. 35 SUBSTITUTE SHEET ' Summary of the Invention According to the present invention, an add-on ground fault system has been developed which can be connected directly to the inputs of a conventional shunt trip operated circuit breaker. The ground fault system consists of a main transformer that has primary windings connected -directly to conductors leading to the associated circuit 10 breaker and at least one secondary winding to detect any imbalance in the primary windings and to produce an output if the sum of the inputs is not zero. The output is then . 15 processed through electronic circuitry and becomes the power source for activating a shunt trip solenoid of the circuit breaker. The system is also designed for use in a four-wire electrical systems using a 20 separate transformer for the fourth or neutral wire, the output of which is connected to a secondary winding and summed with the main transformer outputs. A third secondary winding of the transformer provides a test function 25 whereby a test voltage can be applied which results in current flow simulating a ground fault to effect an. imbalanced current condition in the primary conductors. More specifically, one embodiment of 30 the ground fault detection system of the present invention includes a summing transformer having three primary windings and three secondary windings with an associated electrical circuit. One of the secondary 35 SUBSTITUTESHEET windings detects an imbalance in the current in the three primary windings. An electronic circuit is connected to the one secondary winding and provides an output when the one 5 secondary winding detects an imbalance in the circuit in the three primary windings. The electronic circuit includes a switch-controlled circuit which selectively turns "ON" and "OFF" to periodically place a relatively low 10 resistance burden on the summing transformer to measure the net circuit current flow. The electronic circuit also includes a voltage regulator for assuring the voltage is at a preselected state prior to measurement of the 1 current flow from the summing transformer. If the current flow, in the summing transformer exceeds a certain level for a preselected time period,- the current flow is utilized for energizing a solenoid that activates the shunt 20 trip in the circuit breaker. The electronic circuit may also include a pick-up circuit for initiating a signal to provide a tripping signal to the time- delay circuit and thereafter provides tripping 25 energy to the solenoid. The control circuit may also include a restraining circuit for providing a signal to the circuit breakers that are located upstream of the ground fault detection system to isolate the circuit breaker 30 associated with the ground fault detection system. The ground fault detection system is also designed to be utilized with a three-phase electrical system with or without a neutral 35 SUBSTITUTESHEET conductor. In the case of a system having a neutral conductor, a separate transformer is provided for the neutral conductor, and the neutral conductor is electrically connected to 5 one of the secondary windings of the summing transformer. Any current flow in the neutral conductor will be transmitted to a secondary winding of the summing trans ormer, which will in turn be detected by the secondary winding 10 associated with the control circuit. The control circuit means may also include a test switch means associated with one of the secondary windings of the summing transformer so that an associated voltage 15 source may be applied to the transformer to create an imbalance condition in the primary windings and simulate a ground fault condition. Brief Description of Several Views of Drawings 20 FIG. 1 is a schematic illustration in block form of the electronic circuit forming part of the ground fault detection system; FIG. 2 is a perspective view of the add-on module and an associated circuit 25 breaker; and, FIG. 3 is a detailed diagram of the ground fault electronic circuit.. Detailed Description 30 While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail a preferred embodiment of the invention with the understanding that the 35 SUBSTITUTE SHEET present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiment 5 illustrated. Referring to FIG. 2, an add-on ground fault module, designated by reference numeral 10, is interconnected with* a conventional shunt trip operated circuit breaker 12 that 10 incorporates a shunt trip solenoid for interrupting the circuit breaker in the event of an overload condition. The circuit breaker 12 may be of the type sold by the Square D Company and includes a manual switch 14 in 15 addition to the shunt trip solenoid (not shown) for interrupting the circuit. As is conventional, the circuit breaker normally has three conductors A, B and C connected to the OFF side through input sockets (not shown) of 20 the circuit breaker. According to one aspect of the present invention, the add-on module 10 incorporates standard lugs (not shown) that are received into the input sockets of the circuit 25 breaker and the module 10 has three input terminals 16 for receiving the respective conductors A, B and C of a three-phase electrical syte . The module 10 has a plurality of connector terminals labeled by 30 numbers 1-8 in FIG. 2 which are connected to the circuit illustrated in FIG. 1. An electronic circuit incorporated into the ground fault module 10 is illustrated schematically in FIG. 1. The circuit includes 35 SUBSTITUTESHEET a transformer Tl having primary windings N4, N5 , N6 for connection to the three A-C power lines A, B and C. Transformer Tl also, has three secondary windings Nl, N2 and N3. 5 Secondary winding N3 is connected through conductors 30 and a switch 32 to external terminals 7 and 8 of module 10 to provide a test function, as will be described later. The secondary winding N2 is connectable 0 by conductors 34 through terminals 5 and 6 of module 10 to the secondary winding 36 of a neutral transformer T2. Transformer T2 has its primary windings N connected to a neutral conductor (not shown). The first secondary 15 winding Nl is utilized as a detector for detecting a ground fault condition in any one of the primary windings N4, N5 and N6 or neutral winding N. Secondary winding Nl is connected 20 through a full-wave bridge rectifier CRl to the electronic circuitry, generally indicated by reference numeral 40. The electronic circuitry 40 includes a voltage regulator VR, a switch control circuit 43, first and second switches 25 and associated circuits Si and S2, a capacitor Cl, a delay circuit 50, a pick-up circuit 52, and a restraint output circuit 54. The foregoing circuitry is coupled between the bridge CRl and a shunt trip solenoid STS that 30 is part of the circuit breaker 12. The rectifier bridge CRl is also connected to the trip solenoid STS through a diode CR2 and conductor 58. 35 SUBSTITUTESHEET The various components and functional embodiments of the control circuit 40 are illustrated in more detail in FIG. 3. In FIG. 3, the output from the full wave rectifier 5 bridge CRl is coupled through diode CR2 to the switch control circuit 43. Diode CR2 also connects through resistor Rl to voltage regulator component Ul and through lead LI to various other components, as will be explained. 10 A capacitor Cl is connected across the input of switch control circuit 43. The input from rectifier CRl is impressed across capacitor Cl and is also applied across zener diode 21 and series connected resistors R2 and 15 R3 of control circuit 43. The cathode of zener diode 21 is connected to lead 58 and its anode is connected through series resistors R2, R3, R5 and R6-7 to lead Ll. The junction of resistors R2 and R3 is connected to the non- 20 inverting input terminal 9 of comparator U2-1 of switch control circuit 43 and the junction of resistors R5 and R6-7 is connected to the inverting input terminal 8 of comparator U2-1. A reference voltage is coupled from voltage 25 regulator Ul to the comparator U2-1 through resistor R6-7. The output of the comparator U2-1 is connected through reverse connected diode CR3 to the base of an NPN transistor Q2 which forms 30 part oj- the first switch SI. Switch SI comprises transistor Q2 which drives a PNP transistor Ql. The emitter of the transistor Ql is connected through lead 60 to the output of the bridge CRl, for purposes to be described 35 SUBSTITUTE SHEET later. The collector of transistor Ql is coupled to the junction of resistor R9 and RIO. The pick-up circuit 52, is coupled between switches SI and S2 and is also 5 connected between the switch SI and the restraint output circuit 54. Comparator U2-2 of pick-up circuit 52 has its output connected through a diode CR6 to the- inverting input 7 of a second comparator U2-3. The restraint 10 circuit 54 receives an enabling signal from comparator U2-3 and provides an output restrain signal through an NPN transistor Q4, as will be described. Capacitor C4 and comparator U2-4 form 5 a part of time delay circuit 50, as will be described. In the circuit of FIG. 3, approximately five volts is applied from voltage regulator Ul to the junction of 20 resistors R5 and R6-7 and hence to inverting terminal 8 of the comparator U2-1. Assume the condition that the capacitor Cl is charging. In this condition, a low voltage is applied to the non-inverting input 9 of the comparator U2-1, 25 and the output of comparator U2-1 is low. As the capacitor Cl charges, the voltage to the non-inverting input 9 of the comparator U2-1 exceeds the reference voltage at the inverting input 8 and the output of comparator U2-1 30 changes from a low output to a high output. This occurs when the voltage charge on the capacitor Cl reaches a predetermined level of about 48 volts. 35 SUBSTITUTE SHEET As a result of the comparator U2-1 changing state, the transistor Q2 of the switch SI changes from a non-conducting to a conducting state and this causes transistor Ql 5 of switch SI to change from a non-conducting to a conducting state. When transistor Ql conducts, a very low resistance burden is placed on the summing transformer Tl through the lead 60. During the time the transistor Ql 1 0 is conducting, the summing transformer Tl accurately measures the net current flow. The current from the secondary winding Nl flows through transistor Ql and resistor R9 as an input to the relay pick-up circuit 52. The 1 5 resulting voltage developed across resistor R9 is coupled to the non-inverting input 5 of comparator U2-2. Capacitor C6 in conjunction .with resistor RIO act as an electrical filter for high frequency noise. 20 During this time when the circuit is metering the current, the power is supplied to the circuit by the storage capacitor Cl. When 25 the capacitor Cl discharges to a lower voltage of about 44 volts, the comparator U2-1 changes states, and this will cause transistor Ql to change from a conductive to a non-conducting state. This will again allow the capacitor Cl 30 to recharge to its maximum voltage of 48 volts. Note that the operation of the voltage regulator including Ul, resistor Rl and capacitor C8 is such that its output reaches the regulated voltage prior to the change in 35 SUBSTITUTE SHEET state of comparator U2-1 and transistors Ql and Q2. When the value of the metering signal voltage appearing at the non-inverting terminal 5 of the comparator U2-2 of pick-up circuit 52 exceeds the reference voltage appearing at inverting input terminal 4 of comparator U2-2, the output of the comparator U2-2 changes from a low to a high output. This results in charging of the capacitor C3 of restraint circuit 54. Capacitor C3 is charged through diode CR6. Capacitor C3 is also connected to the inverting input of comparator U2-3 of pick¬ up circuit 52, and when capacitor C3 charges, it causes comparator U2-3 to change from a low to a high output. A high output from the comparator U2-3 causes NPN transistor Q4 to conduct to provide a ' restraint signal to an upstream circuit breaker. If the pick-up output from the comparator U2-3 remains high, the circuit will provide tripping energy to the tripping solenoid STS at the end of the time delay as will now be explained. When pick-up occurs, capacitor C4 of the time delay circuit 50 is allowed to charge through resistor R6-2 and the series •resistors R15 and diode CR8. Capacitor C4 also receives a component of charge from the fault current appearing across resistor R9. This charge flows through resistor R14 and diode CR7. This second current path reduces the time delay as fault current increases. Diode CR9 limits the contribution from resistor R9 at very high fault levels. The time delay is also . SUBSTITUTE SHEET varied by adjusting the value of resistor R15. If the pick-up signal remains high, capacitor C4 will charge to the reference voltage which is impressed on non-inverting terminal pin 10 of comparator U2-4 to provide an output to switch S2. This positive output signal from the comparator U2-4 is applied t through resistor -R2-3 and lead L3 to the gate of the FET Q3 causing it to change from a non-conducting to a conducting state. This will allow the capacitor Cl to discharge through the tripping solenoid STS and the tripping indicator solenoid TIS resulting in the tripping of ;the circuit breaker and an indication of the tripping event. When the output of the comparator U2- 2 goes from a low to a high voltage level, it causes a change in the output of comparator U2- 3 which in turn causes transistor Q4 to conduct. This develops a five-volt signal across the resistor R24 of restraint circuit 54. The output of the restraint circuit 54 will thus provide a reference voltage signal to an- upstream breaker whenever a ground fault is detected and the pick-up is exceeded. While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents :..ay be substituted for elements thereof without departing from the broader aspects of the invention. Also, it is intended that broad claims not specifying details of a particular embodiment disclosed herein as the best mode contemplated for SUBSTITUTE SHEET carrying out the invention should not be limited to such details. Furthermore, while, generally, specific claimed details of the invention constitute important specific aspects of the invention in appropriate instances even, the specific claims involved should be construed in light of the doctrine of equivalents. SUBSTIT U TESHEET

Claims: CLAIMS 1. A ground fault detection system comprising: ς a summing transformer having three primary windings, and at least one secondary winding, said primary windings being connectable to an associated electrical breaker; 10 said secondary winding detecting any current imbalance in the three primary windings; and, an electronic circuit connectable to said secondary winding and providing an output 1 when said secondary winding detects any imbalance in the current in the three primary windings . 2. A ground fault detection system 2o fo a three-phase system having a neutral conductor, a summing transformer having three primary windings, and at least two secondary windings; 25 one of said secondary windings detecting any imbalance in the current flow in said primary windings; an electronic circuit connectable to said cne of said secondary windings and 30 providing an output when said one secondary winding detects any imbalance in the current in the three primary windings; 35 SUBSTITUTESHEET a- neutral transformer connected to the neutral conductor; said neutral transformer electrically connected to provide an output to a second of said secondary windings; and, said first secondary winding summing the currents in the three primary windings and the current provided by the neutral transformer to provide an indication of the balanced and imbalanced ground fault condition in the primary conductors. 3. A system as in Claim 2, further including a third secondary winding, test switch means for connecting said third secondary winding to an associated AC voltage source whereby, when the test switch means is closed, the resulting current flow creates an imbalanced condition in the primary windings to simulate a ground fault. 4. A system as in Claim 1, wherein said electronic circuitry includes: a switch control circuit for ' selectively turning ON and OFF to periodically place a relatively low reistance burden on the summing transformer to measure the net circuit flow; a voltage regulator for assuring the voltage is at a preselected state prior to the measurement of the current flow; a tripping solenoid; a time delay circuit for delaying ''input signals to the tripping solenoid; SUBSTITUTE SHEET a pick-up circuit for initiating a signal to provide a tripping signal to the time delay circuit and tripping energy to said solenoid; second switch means for coupling the tripping energy to said solenoid; and, a restraining circuit for providing a signal to circuit breakers located on the lead side of said fault detection system. 10 5. A ground fault detection system comprising, in combination: a main transformer having primary windings and at least three secondary windings, 15 said primary windings being connectable to an associated electrical breaker; a first of said secondary windings being selectively connectable to an AC volt test power source; 20 a switch for connecting said test power source to said one of said secondary windings; and, an electronic circuit, one of said secondary windings being connected to said 25 electronic circuit, said electronic circuit sensing the current output of said primary windings to provide an output proportional to the instantaneous sum of the currents in said primary windings. 30 6. A system as in Claim 5 wherein said electronic circuitry comprises: capacitor means chargeable to a preselected voltage level; 35 SUBSTITUTE SHEET a relative low resistance burden; first switch means coupling said burden to said transformer when said capacitor is charged to said preselected voltage level; means for measuring the net current flow in said transformer; means for developing a metering voltage representative of said net current flow; 10 a relay pick up circuit for detecting said metering voltage; said capacitor providing the power to said circuit during the time the circuit is metering said current and thereby discharging; 15 said pick up circuit being energizable in response to a metering signal above a selected reference; a time delay means for providing a preset time delay and actuatable in response to 20 a signal from said pick up circuit; and, a tripping relay energizable by said time delay means at the end of said preset time delay. 25 7. A system as in Claim 5 wherein a solenoid of a tripping relay is connected to said capacitor means and said capacitor means selectively discharges through said solenoid resulting in the tripping of an associated 30 breaker. 8. A system as in Claim 5 further including a restraint circuit operable in response to metering signal above said 35 SUBSTITUTESHEET reference level to provide a fault indicating signal to an upstream breaker. 10 15 20 25 30 35 SUBSTITUTESHEET

Inventors: ZYLSTRA HENRY J, ZYLSTRA, HENRY, J.
Applicants: SQUARE D CO, SQUARE D COMPANY
Application year: 1988
Main classification: H02H3
IPC codes: H02H3