Abstract:
A combination current sensor and relay has an improved housing. In one aspect, the housing includes light emitting diodes on an upper surface that indicate open circuit and short circuit conditions. In another aspect, the housing includes a securement structure for a circuit board that includes the transformer and switches for device operation, together with aligned openings therein for routing wires to external devices. In another aspect, a multiple position switch is included on the upper surface that indicates multiple modes of operation of the device. In another aspect, the housing may be assembled in multiple parts by affixing a first portion to a support, a circuit board to the first portion, and a second portion to the first portion. In another aspect, the housing is suitable for engagement to alternatively a junction box and a duplex box. In another aspect, the configuration of the upper surface provides usability advantages.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is a continuation of application Ser. No. 10/982,752 filed Nov. 2, 2004, now U.S. Pat. No. 7,333,345 B2; which is a continuation of application Ser. No. 10/013,772, filed Dec. 10, 2001, now U.S. Pat. No. 6,856,515; which is a Continuation of application Ser. No. 09/636,296, filed Aug. 10, 2000, now U.S. Pat. No. 6,331,821; which claims the benefit of U.S. Provisional Application No. 60/145,616, filed Jul. 26, 1999. 

   BACKGROUND OF THE INVENTION 
   The present invention relates to a housing for a combination current sensor and relay. 
   One of the trends in many industrial environments is to use an ever increasing number of electrical devices that include small motors, such as motors incorporated with fans. Typically such small motors only draw a limited amount of current, such as 1-10 amps. To provide fault detection for electrical devices having limited current requirements, a current sensor is electrically interconnected with the power cable to the electrical device to sense the electrical load current. The current sensor may include an electrical interconnection to a remotely located control panel to provide a signal to the control panel representative of the current within the power cable. It is desirable to locate such a current sensor within a housing, such as a starter housing within a substation. The current sensor or an associated relay may be interconnected to a separate starter, if desired. A relay is typically electrically interconnected between the remotely located control panel and the electrical device to receive a control signal from the control panel and in response selectively enable or disable power to the electrical device. Like the current sensor, such a relay may be located within the starter housing. In addition, the relay may function as the starter if the power rating of the relay is appropriate. Because of decreasing starter housing sizing, the relay and current sensor may be enclosed within a single unitary housing. Such a device is disclosed in U.S. Pat. No. 5,808,846, incorporated by reference herein. 
   Referring to  FIG. 1 , Functional Devices, Inc. of Russiaville, Ind., manufacturers a Model RIBXLSA combination current sensor and relay  10 . Referring to  FIG. 1 , the device  10  includes a start/stop relay  12  that is energized or otherwise controlled by the digital output of a controller  14 . Power from a power source  16  is provided by a wire  18  which is interconnected to the start/stop relay  12  of the device  10 . The start/stop relay  12  is likewise interconnected to an internal sensor  20  by a wire  22 , namely, a current sensor in the form of a transformer. The output of the internal sensor  20  is interconnected to a load  24  by a wire  26 . The load  24  is interconnected to the source  16  by a wire  28 . Accordingly, a loop for current flow is provided by wire  18 , the start/stop relay  12 , the wire  22 , the internal sensor  20 , the wire  26 , and the wire  28 . When the start/stop relay  12  is open, as a result of the controller  14 , the power to the load  24  is interrupted (open circuit). Likewise, when the start/stop relay  12  is closed, as a result of the controller  14 , power is provided to the load  24  (short circuit). Accordingly, the controller  14  may control power to the load  24  by energizing and de-energizing the start/stop relay  12 . The device  10  may include a closed/open/auto switch  21  for enabling the operation of the start/stop relay  12 . Other applications of the device  10 , are illustrated in  FIGS. 2 and 3 . A solid state switch  21  measures the current level to the load  24  and provides an open/closed signal to the controller  14  based on the current level. 
   Referring to  FIG. 4 , the combination current sensor and relay  10  Model RIBXLSA from Functional Devices, Inc. is packaged in a rectangular housing  40  with a threaded opening  42  on the lower portion though which are passed a pair of wires  18  and  26 . The wires  18  and  26  are connected in series with the power cable to the load as shown in  FIGS. 1-3 . Internal to the housing  40  are a set of four wire connectors  110  to which the control wires to the controller  14  are attached. To access the four wire connectors  110  the rear panel  44  is removed. The control wires may be passed through an opening  46  in the upper left hand side, an opening  48  in the upper right hand side, or both, as desired. The textual and graphical indication for which connectors correspond to the solid state switch  21  and to the relay  12  are provided on the back panel of the device. A set of three light-emitting-diodes  50 ,  52  and  54  are provided on the top of the housing  40 . The right hand diode  54  provides an indication as to whether the relay is energized. The left hand pair of diodes  50  and  52  provides assistance in adjusting the set point for the current level of the solid state switch  21 . When the central diode  54  is activated the current is over the trip point When the left hand diode  50  is activated the current is under the tri point. A potentiometer that is accessed within the housing  40  when the back  44  is removed adjusts the set point for the switch  21 . The switch  21  includes some hysteresis. To adjust the device  10 , the potentiometer is decreased (turned counterclockwise) until the central diode  52  turns on (may already be on). The potentiometer is then increased (turned clockwise) until the left hand diode  50  turns on. Then the potentiometer is decreased (turned counterclockwise) until the central diode  52  turns on. This properly adjusts the current level. The instructions for adjusting and the meaning for the light emitting diodes are provided within the housing  40 . A closed/open/auto switch  56  is provided on the left hand panel of the housing  40 . Likewise, the instructions for the settings of the switch  56  are provided on the back panel of the housing  40 . The entire housing  40  is secured to a wall by a set of four screws at the corners thereof. 
   SUMMARY OF THE INVENTION 
   The present invention overcomes the aforementioned drawbacks of the prior art by providing a combination current sensor and relay with an improved housing. The housing has several aspects which result in improved functionality. In one aspect, the housing includes light emitting diodes on an upper surface that indicate open circuit and short circuit conditions. In another aspect, the housing includes a securement structure for a circuit board that includes the transformer and switches for device operation, together with aligned openings therein for routing wires to external devices. In another aspect, a multiple position switch is included on the upper surface that indicates multiple modes of operation of the device. In another aspect, the housing may be assembled in multiple parts by affixing a first portion to a support, a circuit board to the first portion, and a second portion to the first portion. In another aspect, the housing is suitable for engagement to alternatively a junction box and a duplex box. In another aspect, the configuration of the upper surface provides usability advantages. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a diagram of a HID single fixture with a combination current sensor and relay device. 
       FIG. 2  is a diagram of an exhaust fan with a combination current sensor and relay device. 
       FIG. 3  is a diagram of a panel mounted combination current sensor and relay device. 
       FIG. 4  is a pictorial view of a combination current sensor and relay. 
       FIG. 5  is a pictorial view of an exemplary embodiment of a combination current sensor and relay housing of the present invention. 
       FIG. 6  is a top view of the housing of  FIG. 5 , including a base portion and a top portion. 
       FIG. 7  is a top view of the base portion of  FIG. 6 . 
       FIG. 8  is a top view of the base portion of  FIG. 7  with a circuit board secured thereon. 
       FIG. 9  is a side view of flexible members securing the circuit board to the base portion. 
       FIG. 10  is a pictorial view of the housing being secured to a 4S junction box. 
       FIG. 11  is a pictorial view of the housing being secured to a duplex box. 
       FIG. 12  is a pictorial view of the housing being secured to a surface. 
       FIG. 13  is a top view of a threaded member. 
       FIG. 14  is an exemplary circuit diagram for the present invention. 
       FIGS. 15A and 15B  is an alternatively exemplary circuit diagram for the present invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   The present inventors came to the realization that while the housing for the aforementioned combination current sensor and relay RIBXLSA is functional, it has limitations that become important when the device is mounted in a small enclosure, such as a starter housing within a substation. 
   First, the three status light emitting diodes are on the top surface of the housing making them difficult to observe if the device is mounted deep within a starter housing at any level other than the users eye level. For example, when mounted in a starter housing near the floor, the user will need to excessively bend down to observe the light emitting diodes on the top of the housing. Also, when mounted in a starter housing near the ceiling, the light emitting diodes on the top surface may be obscured by the upper portion of the front panel. In addition, the textual and graphical indications for the meaning of each diode are provided on the back panel of the housing, which is not observable when mounted in the starter housing. Accordingly, the user must memorize the meaning of each of the diodes or carry an extra device to read the textual and graphical indications therefrom. 
   Second, the closed/open/auto switch is located on and independently secured to the side of the housing making it difficult to operate when the housing is mounted adjacent an upright left hand wall of the starter enclosure or another device. Also, the switch is difficult to observe if the user is not directly aligned with the left side of the housing. In addition, the textual and graphical indication for the meaning of the three settings of the switch is provided on the back panel of the housing, which is not observable when mounted in the starter housing. Accordingly, the user must memorize the meaning of each of the positions or carry an extra device to read the textual and graphical indications therefrom. 
   Third, the rear panel of the housing must be removed in order for the control wires to be installed. This necessarily requires the device not be mounted within the starter housing because when mounted the rear panel is secured to the wall of the starter housing. Unfortunately, it is cumbersome to install the control wires when the device is unmounted and thereafter mount the housing to the wall of the starter housing with the control wires attached. In addition, if the user is not careful the control wires may end up being to short to mount the device where intended. Further, the textual and graphical indication for the function of each of the connections for the control wires is provided on the back panel of the housing. 
   Fourth, the housing is installed on a flat surface, such as the back wall of a starter housing through a set of four openings provided therein. In addition, the present inventors came to the realization that such a combination current sensor and relay would be more versatile if mountable on a duplex box, a junction box, and a surface, and electrically connected thereto. 
   Referring to  FIGS. 5 and 6 , the improved housing  70  for a combination current sensor and relay of the present invention includes two separate portions, namely a base portion  72  and a top portion  74 . Referring also to  FIG. 7 , the base portion  72  includes a pair of supports  74   a  and  74   b  and a central set of fingers  76  which supports an enclosed circuit board  73  (see  FIG. 8 ). A pair of resilient members  78   a  and  78   b  flexibly bend and engage the circuit board with protrusions to secure it in place within the housing  70  on the supports. To remove the circuit board  73 , the flexible resilient members  78   a  and  78   b  are pulled away from the circuit board  73  thereby releasing the circuit board  73  (see  FIG. 9 ). This provides an easy way of removing the circuit board  73  from the housing  70  if it needs to be replaced, thereby alleviating the need to replace the entire device. In addition, a pair of openings  80   a  and  80   b  are provided in the back of the base portion  72  in front of the resilient members  78   a  and  78   b  (directly under the protrusions) so that the members may be pulled away from the circuit board  73  by prying with a suitable device, such as a small screwdriver, from the back of the device thereby releasing the circuit board  73 . 
   The base portion  72  includes a pair of openings  82  and  84  at the opposite corners thereof spaced at an appropriate location for securing the base portion  72  to a standard junction box, such as a 4S junction box  86  as shown in  FIG. 10 . The openings  82  and  84  are slightly oblong to permit a little movement of the base portion to make alignment of the openings  82  and  84  with the junction box  86  easier. The base portion  72  also includes a pair of openings  88  and  90  therein at the bottom and top of the central portion spaced at an appropriate location for securing the base portion  72  to a standard duplex box  92  as shown in  FIG. 11 . The top opening  90  is slightly oblong to permit a little movement of the base to make alignment of the openings  88  and  90  with the duplex box  94  easier. In addition, a central opening  96  is provided in the central portion of the base portion  72  to permit the routing of the power wires  18  and  26  therethrough for connection within the junction box  86  or duplex box  94 . Without the central opening  96  in the base portion  72 , the device would need to be mounted to an adjacent surface with the power wires routed therefrom into the junction box or duplex box, which is inconvenient. Further, with multiple openings in the base portion  72 , the same base portion  72  may be installed on multiple boxes, such as the duplex and junction boxes. This reduces the necessary inventory for users and increases the flexibility of the different uses for the device. In addition, with the wires routed through one or more of the openings in the sides thereof, the device may be mounted on a surface, such as a flat surface of a starter housing, as shown in  FIG. 12 . 
   The fingers  76  surrounding (in a circumferential relationship) the opening  96  are spaced to engage the protrusions of a threaded metal member  98  as shown in  FIG. 13 . The threaded metal member  98  is placed within the fingers  76  and thereby prevented from rotating or substantial rotation. The engagement of a threaded member  98  to a pipe is normally performed by pressing engagement of the pipe thereon while turning the pipe. In addition, with the circuit board  73  supported by the fingers  76 , the threaded member  98  will not become disengaged by raising above the fingers  76  when a pipe is rotatably pressingly engaged therewith. 
   The control and power wires may be routed through the openings in the sides, as necessary. The openings defined by both the top portion  74  and the base portion  72  include one or more ribs  100  which engage a protrusion of the threaded member  98  when supported therein. In addition, the ribs  100  are sufficiently recessed so that the face of the threaded member  98  is also in at least in partial face to face opposing relationship with the side. Accordingly, when the top portion  74  and base portion  72  are engaged with one another the threaded member  98  is prevented from significant rotational movement and also prevented from significant lateral movement. Thus the sufficiently threaded member  98  is retained in place to secure a threaded member thereto. 
   The base portion  72  includes a pair of threaded posts  104  and  106  to which a pair of screws are secured through the top portion  74  when engaged therewith. By securing the top portion  74  to the base portion  72 , while the base portion  74  is secured to the supporting device, such as a surface or a box, the top portion  74  may be removed to allow access to the circuit board  73  therein without removal of the entire housing  70  from the supporting device or surface. Accordingly, the base portion  72  may be attached to a supporting surface. Then the circuit board  73  is detached to permit easier assess the central opening  96  in the base portion  73 , if necessary. The power wires  18  and  26  are routed through the appropriate opening and the control wires are attached to the connectors  100  (see  FIG. 8 ). Textual indications indicating the function of each connector  110  are provided on the circuit board  73  adjacent the connector, such as relay (+) (−) and status. Thus, when a user installs the control wires and power wires, the device may be previously secured in the desired location, so that the length of the controls wires and power wires may be accurately determined. Also, the textual and/or graphical indications of the function of the control wires is provided next to the connectors so that it is less likely that the user will install the control wires improperly. In addition, without the need to search for the textual and/or graphical indications for the functions of the connectors  110  the user will likely install the connectors faster. 
   A relay  120 , a transformer  122 , a potentiometer  132 , three light emitting diodes  124 ,  126 ,  128 , the connectors  110 , and a switch  130  are supported by the circuit board  73 . Accordingly, when any of the electrical or mechanical devices fail, the entire circuit board  73  may be easily replaced as a single unit. This alleviates the need to troubleshoot individual components connected to different portions of the housing. The relay may be any type of switching circuit, as desired. The transformer may be directly connected in series or at least partially encircle the power cable. The relay and switch may be designed to sense any type of signal, such as a voltage, current, short circuit, and open circuit. The controller is preferably a programmable logic device. 
   Referring again to  FIG. 6 , the top portion  74  is secured to the base portion  72  with a pair of screws. The switch  130  is provided through an opening  136  in the top portion  74 . Locating the switch  130  on the frontal surface permits easy access to the switch  130  and easy identification of the state of the switch. Textual and/or graphical indications  134  for the operation of the switch  130  are provided on the top member. The textual and/or graphical indications  134  of the operation of the switch  130  being provided on the front surface make it easy for the user to recall the operations of the switch, without the need to look at other uninstalled devices, a manual, or rely on the user&#39;s memory. In addition, the switch  130  is recessed from the upper surface  138  of the top portion  74  which reduces the overall height of the device while simultaneously locating the switch  130  at a location less likely to become inadvertently bumped thereby interrupting or unintentionally providing power to the load. The upper upright surface  140  above the left hand upright surface  142  partially surrounding the switch  130  provides a stop for a user&#39;s finger to hold the finger in position above the switch  130  so that the switch  130  may be more easily operated, especially when the user is wearing gloves. In addition, such upright surfaces  140  and  142  stop and maintain the finger of a user in position above the switch  130  while testing the electrical load even when the housing  70  is in an awkward location, such as the back of a starter housing. 
   The light emitting diodes  124 ,  126  and  128  and set point adjustment  132  (potentiometer) are provided through a set of openings  144  in the top portion  74 . Locating the light emitting diodes on the front (upper) surface permits easy reading of the status and adjustment of the set point from the front of the housing  70 . Textual and/or graphical indications  146  for the function of the set point and light emitting diodes are provided on the top portion  74 . The textual and/or graphical indications  146  of the operation of the diodes and set point being provided on the front surface  148  make it easy for the user to recall the operation of the diodes and set point, without the need to look at other devices nor open the device to adjust the set point. In addition, the set point and light emitting diodes are proximate the switch and recessed from the upper surface  138  of the top portion  74  and further recessed from the surface  137  with the switch  130 . When the user is adjusting the switch  130  his finger will likely partially obscure from view the surface  148  proximate the light emitting diodes and set point. However, by further recessing the surface  148  proximate the light emitting diodes the user will be more likely to observe the status of the light emitting diodes by observing the diodes at an angle thereof under the finger. It is unlikely that the finger of a user on the switch will totally obscure the surface  148  further recessed therefrom. 
   Referring to  FIG. 14 , an exemplary circuit (similar in functionality to  FIGS. 1-3 ) includes a start/stop relay, an internal current sensor, and a switch circuit. The power cables are interconnected to a terminal block. The terminal block is interconnected to a switch circuit that provides an on-off-on functionality. With the switch in the upper position, referred to as the hand mode, the terminal block is electrically connected across a transformer with the start/stop relay effectively removed from the circuit. Any power from the source to the load is provided without interference by the combination current sensor and relay device. With the switch in the central position, referred to as the off mode, the terminal block is open circuited. Any power from the source to the load is open circuited. With the switch in the lower position, referred to as the auto mode, the electronics are enabled. Any power from the source to the load is provided dependent on the status provided to the relay coil contacts from the controller. 
   For the auto mode the connection of the contact jumper provides either a normally closed or normally open functionality. Interconnecting pins  1  and  2  provides a normally closed condition to the relay, while interconnecting pins.  2  and  3  provides a normally open condition to the relay. The power from the controller is preferably 24 volts, either AC or DC. If the input signal is AC then diode D 1  rectifies the signal and provides a DC voltage between the capacitor and the resistor. Light emitting diode D 2  provides a status indication to the user that the relay is energized. Energizing or de-energizing the relay changes its state and hence whether the circuit to the load is open or short circuited. 
   The primary of a transformer, generally referred to herein as an internal current sensor, is electrically interconnected between the switch and the terminal block. The secondary of the transformer provides a current (or voltage) signal representative of the current flowing between the terminals of the terminal block, and hence to the load. A pair of diodes provides alternating current clipping at 6.3 volts to protect the remaining portions of the circuit and also provide a reference voltage at the upper terminal of the secondary of the transformer. A scaling resistor and potentiometer provides a scaled voltage at the base of the diode. The diode and capacitor provide a ½ wave rectifier functionality. A diode clamps the voltage to a maximum of 9.1 volts. A positive voltage detector, such as a 4.1 volt detector, interconnects VDD to the output when the difference across its terminals is greater than approximately 4.1 volts. The positive voltage detector interconnects VSS to the output when the difference across its terminals is less than approximately 4.1 volts. The PDD has some built in hysteresis to avoid repetitively switching near the switching point, such as 4.1 volts. When the output of the PDD is high then transistor Q 5  is activated with diode D 4  indicating an over current situation. When the output of the PDD is low then transistor Q 5  is not activated and diode D 5  is activated indicating an under current situation. By adjustment of the potentiometer in combination with the diode indications, the suitable current level may be obtained. 
   When the output of the PDD is high then transistors Q 4 A and Q 4 B are activated thereby shorting the status terminals together. This permits DC or AC current to flow between the contacts. A pair of diodes provides excess voltage protection, such as 47 volts. When the output of the PDD is low then Q 4 A and Q 4 B are not activated thereby providing an open circuit between the terminals. 
   Referring to  FIGS. 15A and 15B , an alternative circuit provides an additional set of contacts. Preferably the upper PDD and associated circuit provides an over current indication, such as a locked rotor. Preferably the lower PDD and associated circuit provides an under current indication, such as a belt loss. Accordingly, the output terminals provide both an over current and an under current indication. It is noted that the field effect transistors are provided for a normally open circuit and alternatively the npn bipolar transistors are provided for normally closed circuit. Both are not typically simultaneously included, or otherwise electrically interconnected, in an actual circuit. 
   The terms and expressions that have been employed in the foregoing specification are used as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims that follow.