Patent Publication Number: US-7214895-B2

Title: Illuminated disconnecting handle for use with CDM

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   Not applicable. 
   STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
   Not applicable. 
   BACKGROUND OF THE INVENTION 
   The present invention relates to electrical circuit disconnecting means (CDM) for mounting in cabinets and having a forwardly-extending, rotary disconnect that engages a handle on a cabinet door when the cabinet door is closed, and in particular, to an improvement in such CDM that provide visual indications of assembly states outside the cabinet as well as provide auxiliary contacts within the cabinet that are controllable irrespective of the position of the door. 
   Hereinafter, unless indicated otherwise and in order to simplify this explanation, the present invention will be described in the context of a breaker assembly that includes a circuit breaker. Nevertheless, it should be appreciated that the concepts described herein are also applicable to other types of CDM including fusible disconnects, non-fused disconnects, etc. 
   Referring to  FIG. 1 , a standard breaker assembly  10  of the prior art includes several components mounted within a cabinet  12  including a door  20  and several components mounted to the door  20 . In the illustrated example, the components within the cabinet include a circuit breaker  16 , a power contactor  18  and a disconnector or disconnect means  33 . Circuit breaker  16  is a three phase breaker including three switches  25 ,  26  and  58  as well as an auxiliary switch  29 . 
   Contactor  18  includes three power contacts  56 ,  50  and  42 , a relay coil  44  and two control or auxiliary contacts  51  and  54 . Contacts  56 ,  50 ,  42  and  54  are normally open while contact  51  is normally closed. 
   Three phase high voltage power is provided to breaker  16 , a separate phase provided to each of switches  25 ,  26  and  58 . Similarly single phase low voltage power is provided to switch  29  as well as to each of auxiliary contacts  51  and  54 . Each of switches  25 ,  26  and  58  is linked in series with a separate one of power contacts  56 ,  50  and  42  while auxiliary switch  29  is linked in series with coil  44 . The output of each power contact  56 ,  50  and  42  feeds a different phase of a three phase load (e.g., a motor). Each of power contacts  56 ,  50  and  42  as well as auxiliary contacts  51  and  54  is controlled by relay coil  44  such that, when coil  44  is de-energized, the contacts assume their normal condition and, when coil  44  is energized, the contacts transition to their exited states (i.e., normally open contacts close and normally closed contacts open). 
   In operation, breaker  16  is automatically controlled as a function of system operating parameters to either close switches  25 ,  26  and  58  thereby providing power to contactor  18  and to close switch  29  thereby exciting coil  44  and in turn transitioning contacts  56 ,  50 ,  42 ,  51  and  534  or to open switches  25 ,  26 ,  58  and  29  thereby cutting off power to contactor  18  and de-energizing coil  44 . 
   Referring still to  FIG. 1 , components in the illustrated example that are mounted to cabinet door  20  include a handle member or handle  24  and “On” and “Off” lights  60  and  22 , respectively. On light  60  is linked to auxiliary contact  54  and lights up when contact  54  is closed. Similarly, light  22  is linked to contact  51  and lights up when contact  51  is closed. 
   Manual disconnector  33  is a mechanical assembly that links to handle  24  and that can be used to manually open the switches in breaker  16 . To this end, referring to  FIGS. 1 and 2 , a shaft  30  extends from breaker  16  toward door  20  and is rotatable about its axis of extension to electrically open and close breaker switches  25 ,  26 ,  58  and  29 . 
   Handle  24  is configured to engage the distal end  31  of shaft  30 . In particular, a pair of cylindrical locking pins  34  extends horizontally outwardly from either side of the distal end  31  of shaft  30 . An extension member  32  extends from the rear side of handle  24  through an opening in door  20 , forms a corresponding keyhole  36  that faces into cabinet  12  and includes a first horizontally extending slot  38  sized to receive locking pins  34 . Key hole  36  further includes a second vertically extending slot  40  that intersects with slot  38  and is sized to receive the outer end  31  of shaft  30 . 
   During operation, when door  20  is closed, shaft  30  and corresponding locking pins  34  are inserted into keyhole  36  of extension member  32 . Handle  24  and member  32  are subsequently rotated counterclockwise along the direction of arrow A, which causes keyhole  36  to correspondingly rotate shaft  30  counterclockwise in the direction of arrow B. Here, rotation in the direction of arrow B closes the breaker switches while rotation in the opposite direction manually opens the switches. As handle  24  is rotated in the direction of arrow A, a door latch (not illustrated) locks door  20  in a closed position. Accordingly, in order to subsequently open door  20 , handle  24  is rotated clockwise to unlock door  20  and automatically rotate shaft  30  to open the breaker switches and cut off power to the load. Thus, a user is therefore advantageously unable to access the interior of cabinet  10  without first disconnecting the power contactor  18  from the power source via handle  24 . 
   Here it should be appreciated that the breaker system described above is simplified and is only exemplary and that many other more complex breaker systems exist. For instance, in some cases the breaker  16  may includes many more switches and/or may feed additional contactors or other relay components. As another instance, additional auxiliary contacts may be provided as well as additional lights to indicate other system and component transitional states. 
   Unfortunately, while the above described assembly facilitates relatively safe breaker operation, the assembly has several shortcomings. First, when assembly components fail, it is relatively difficult to determine the cause of failure using the above described assembly. To this end, referring still to  FIGS. 1 and 2 , assume that attempts to provide power from the supply lines to the load through cabinet  12  have failed. To identify the cause of failure, with the cabinet door closed, a system operator may attempt transitioning the assembly components and listen for audible tell tale signs of what is going on inside the cabinet. Unfortunately this solution is not very useful as audible noise from the closed cabinet is often difficult to ascribe to the various components mounted therein when the door is closed. 
   Another solution for determining the source of failure is to open up the cabinet door  20  and visually inspect the components inside the cabinet  12 . Consistent with the description above, to open door  20 , a system operator turns handle  24  and disconnector  33  to the off position thereby cutting power to contactor  18  and to coil  44 . Thereafter, the operator opens door  20  to observe and inspect the components mounted in cabinet  12 . While some failures result in easily observable damage to components, in many cases failures do not cause visually recognizable damage. For instance, in some cases normally open power contactor contacts may stick or fuse closed and the fused contacts may not be positioned in any easy to observe orientation or, the source of the sticking may not be readily visually observable. In other cases additional relay contacts may be stuck in abnormal transitional states. In still other cases one or more of the lights (e.g.,  60 ,  22 , etc.) used to indicate handle and system states may be burnt out. 
   Still one other solution for identifying the source of failure is to cause the cabinet mounted components to transition between states while the cabinet door is open. Thus, for instance, referring again to  FIG. 1 , with door  20  open, a system operator may use a pliers or the like to manually rotate shaft  30  into the On state wherein switches  25 ,  26 ,  58  and  29  are closed at which time coil  44  should excite and transition contacts  56 ,  50 ,  42 ,  51  and  54 . When contactor  18  transitions between states, a noise can typically be heard (e.g., “ker klunk”) which is recognizable as a state transition. Thereafter the user can transition the breaker again by turning the shaft in the opposite direction to the Off position. While processes that provide power to power contactors and to the power contactor coil while the cabinet door is open are known, clearly these processes are relatively hazardous due to power flow and therefore should be avoided whenever possible. 
   Second, the assembly described above requires many parts, requires a good deal of time and labor to configure and therefore is relatively expensive. For instance, three separate holes have to be formed in door  20  to mount handle  24  and lights  60  and  22  and then each of those components have to be separately mounted. In many cases the mounting structure for each of the components includes several screws or the like. Exacerbating matters, many breaker assemblies will include several additional lights and control tools such as buttons, knobs, etc, each of the control tools requiring its own door hole or holes to accommodate mounting assemblies. As another instance, after lights are mounted to door  20 , wiring has to be run form the lights to the associated auxiliary contacts and power source which increases configuration costs and time considerably. 
   Third, in most cases breaker assemblies cannot be easily modified to alter assembly functionality. Thus, for instance, where a system operator wants to modify the auxiliary contact logic so that light  60  marked in  FIG. 1  as “On” instead illuminates when the handle is in a tripped position, the operator has to rewire light  60  to other system components and, in fact, may also have to add additional components (e.g., another relay) to the assembly. 
   Fourth, when separate components are provided on door  20  to facilitate control and to indicate assembly states, the front face of the door becomes excessively crowded and cumbersome to use. This is particularly true in cases where the number of status or state lights is appreciable. 
   Thus, a need exists for a simple, easy to configure, aesthetically pleasing, relatively inexpensive handle assembly that eases the task of diagnosing the health of breaker components. 
   BRIEF SUMMARY OF THE INVENTION 
   It has been recognized that a handle assembly may be provided for interacting with a circuit disconnect means where the handle assembly includes auxiliary contacts that are activated by the handle assembly movement itself and independently of the state of the disconnect means. Here, the handle mounted auxiliary contacts can be used to control and test control circuitry within the cabinet with the cabinet door open or closed by placing one or more of the handle controlled contacts in control circuits. In addition, the auxiliary contacts can be linked to lights that reside on the external surface of a cabinet door so that contact state can be visually identified. Moreover, the contacts can be used as trip indication contacts (e.g., linked to trip lights), on/off status contacts (e.g., linked to on/off lights), etc. 
   It has also been recognized that one or more lights can be provided as integral parts of a handle assembly thereby reducing the costs associated with assemblies that require both a handle and one or more lights as well as reducing the amount of labor required to assemble the assembly. In at least some embodiments, where lights are provided as part of the handle assembly, electricity can be provided to the lights through the same door opening through which the handle extends to link to the disconnect means. 
   Moreover, it has been recognized that both lights and auxiliary contacts can be provided as part of a disconnect handle assembly and additional functionality can be provided. For instance, the contacts may be linked in series with the lights to indicate handle positions. In some cases some of the lights may be linked to the handle mounted auxiliary contacts while other lights are linked to contacts within the control circuitry in the cabinet. Other configurations are contemplated. 
   Consistent with the above, at least some inventive embodiments include an apparatus for use with a control assembly including a power source and a circuit disconnector located on a first side of a planar member forming an opening, the disconnector including a first mechanical linkage having open and closed positions, the apparatus for manipulating the mechanical linkage between the open and closed positions and visually indicating on a second side of the planar member at least a first state of the control assembly when the first state occurs, the apparatus comprising a handle assembly including a handle member moveable between at least first and second positions and positioned on the second side of the planar member adjacent the opening, an extension member rigidly connected to and extending from the handle member through the opening and forming a second mechanical linkage at a distal end that is linkable with the first mechanical linkage on the first side of the planar member, the extension member moving the first mechanical linkage between the closed and open positions when the handle is moved between the first and second positions, respectively and at least a first light emitter positioned on the second side of the planar member and at least a first contact linkable between the power source and the first light emitter that closes to provide power to the first light emitter when the first state occurs. 
   In addition, some embodiments include a handle assembly for use with a control assembly including a power source and a circuit disconnector located on a first side of a planar member forming an opening, the disconnector including a first mechanical linkage having open and closed positions, the assembly comprising a handle member moveable between at least first and second positions and positioned on the second side of the planar member adjacent the opening, an extension member rigidly connected to and extending from the handle member through the opening and forming a second mechanical linkage at a distal end that is linkable with the first mechanical linkage on the first side of the planar member, the extension member moving the first mechanical linkage between the closed and open positions when the handle is moved between the first and second positions, respectively and at least a first light emitter positioned on the second side of the planar member and including conducting leads that extend from the first side to the second side of the planar member. 
   Moreover, some embodiments include a handle assembly for use with a control assembly including a circuit disconnector located on a first side of a planar member forming an opening, the disconnector including a first mechanical linkage having open and closed positions, the assembly comprising a handle member moveable between at least first and second positions and mounted on the second side of the planar member adjacent the opening, an extension member rigidly connected to and extending from the handle member through the opening and forming a second mechanical linkage at a distal end that is linkable with the first mechanical linkage, the extension member moving the first mechanical linkage between the closed and open positions when the handle is moved between the first and second positions, respectively, a cam at least linkable to the extension member for movement therewith on the first side of the planar member and at least a first contact including a activation member, the first contact closing when the activation member is activated, the cam, extension member and activation member positionable in a first relative juxtaposition with respect to each other such that when the handle member is in one of the first and second positions, the cam activates the activation member and, when the handle member is in the other of the first and second positions, the cam releases the activation member. 
   These and other objects, advantages and aspects of the invention will become apparent from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention and reference is made therefore, to the claims herein for interpreting the scope of the invention. 

   
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       FIG. 1  is a schematic diagram illustrating a prior art breaker block assembly; 
       FIG. 2  is a partial perspective view of the linking portions of a handle and a disconnect shaft as known in the prior art; 
       FIG. 3  is a perspective view of a circuit breaker block including a handle assembly consistent with certain aspects of the present invention; 
       FIG. 4  is a perspective view of the assembly of  FIG. 3 , albeit with a cabinet door in an open position; 
       FIG. 5  is a front plan view of the handle assembly of  FIG. 3 ; 
       FIG. 6  is a rear plan view of the handle assembly of  FIG. 4 ; 
       FIG. 7  is an exploded view of the handle assembly of  FIGS. 4 and 5 ; 
       FIG. 8  is an exploded view similar to the view of  FIG. 7 , albeit from a different vantage point; 
       FIG. 9  is a cross-sectional view of the handle assembly of  FIG. 5  taken along the line  9 — 9 ; 
       FIG. 10  is a cross-sectional view of the handle assembly of  FIG. 5  taken along the line  10 — 10 ; 
       FIG. 11  is a cross-sectional view of the handle assembly of  FIG. 6  taken along the line  11 — 11 ; 
       FIG. 12  is a plan view of the cam member of  FIG. 7 ; 
       FIG. 13  is a similar to  FIG. 12 , albeit illustrating a second cam member embodiment in a first juxtaposition; 
       FIG. 14  is similar to  FIG. 13 , except that the cam member is in a second relative juxtaposition; and 
       FIG. 15  is a diagram similar to that illustrated in  FIG. 1 , albeit showing one handle assembly embodiment consistent with certain aspects of the present invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring now to the drawings wherein like reference numerals correspond to similar elements throughout the several views and, more specifically, referring to  FIGS. 3 and 4 , the present invention will be described in the context of an exemplary breaker block  70  including a rigid metallic cabinet  71 , a cabinet door  72 , a breaker assembly  78 , a mechanical disconnect assembly  99  and an inventive handle assembly identified generally by numeral  76 . Cabinet  71  is a rectilinear box including a back wall  74  opposite an open front face. Referring also to  FIG. 14 , three-phase power is provided to cabinet  71  via three supply lines (not labeled) and three supply lines exit cabinet  71  and are linked to a load. Breaker assembly  78 , as illustrated in  FIG. 15 , includes a three-phase circuit breaker  416  and a power contactor  418  that are similar to the breaker and contactor described above with respect to  FIG. 1 . In  FIG. 15 , breaker  416  includes three breaker switches  425 ,  426  and  458  while power contactor  418  includes a contactor coil  444  and three power contacts  456 ,  450  and  442 . Switch  425  and contact  456  are linked in series in a first of the three power phases. Similarly, switch  426  and contact  450  are linked in series with the second of the three power phases and switch  458  and contact  442  are linked in series with the third of the three power phases. Contacts  456 ,  450  and  442  are each normally open contacts. 
   Referring still to  FIGS. 3 ,  4  and  15 , disconnect assembly  99  includes a shaft  80  that extends from breaker  416  toward door  72  and is rotatable about its axis of extension to electrically open and close breaker switches  425 ,  426  and  458 . An internal or distal end  160  of a handle assembly extension member  100  is keyed so as to receive and be linkable to distal end  81  of shaft  80 . Herein, in the interest of simplifying this explanation, the specifics with respect to how keyed distal end  160  links to shaft end  81  and latches thereto will not be described in detail. It should suffice to say that the cooperating ends  160  and  81  latch together in a manner similar to that described above with respect to  FIG. 2  such that when distal end  160  is rotated, shaft  80  likewise rotates. In addition, it should be noted that, when shaft  80  is rotated into a position where breaker switches  425 ,  426  and  458  are open, handle assembly  76  can be manipulated to separate ends  160  and  81  so that door  72  can be opened. Similarly, when shaft  80  is rotated such that breaker switches  425 ,  426  and  458  are closed and power is provided to contactor  418 , distal end  160  is latched to end  81  and handle assembly  76  cannot be manipulated to de-latch ends  160  and  81  until the breaker switches are open. 
   Referring to  FIG. 15 , various aspects of the present invention are related to the construction and operation of handle assembly  76 . In at least some embodiments of the present invention, one inventive aspect of handle assembly  76  is that one or more light emitters  140 ,  142 ,  144  and  146  are provided via the handle assembly  76  itself. By providing the light emitters via handle assembly  76 , an esthetically pleasing assembly design results where lights to annunciate handle or breaker block status and the handle mechanism are provided in a relatively compact and elegant package. In addition, by providing the light emitters via handle assembly  76 , in at least some embodiments of the present invention, only a single hole has to be made in cabinet door  72  to mount components that previously required several holes. For instance, where four separate lights and one handle are required to configure a breaker block for a specific application, while prior configurations required five separate door holes, one for the handle assembly and a separate hole for each of the lights, in at least some inventive embodiments, a single handle assembly including a handle and four lights can be mounted in a single door hole and electrical leads for all four lights can pass through the single hole along with the handle component that mechanically links to the disconnect assembly shaft  80 . 
   Moreover, in at least some inventive embodiments a simplified mounting configuration will be employed to mount the inventive handle assembly. For instance, in at least some embodiments a single nut may be provided to secure the entire handle assembly to the door. 
   In addition, referring still to  FIG. 15 , in at least some embodiments of the present invention, one or more auxiliary contacts  108 ,  110 ,  112 ,  114 , etc., may be provided as part of the handle assembly  76  itself that are controllable to transition between closed and open states directly via manipulation of the assembly  76  as opposed to indirectly through the disconnect assembly  99 . Here, because handle member  90  directly controls the state of the auxiliary contacts that comprise part of the handle assembly  76 , the handle assembly  76  can be used to transition the states of the contacts independent of whether or not door  72  is open or closed (i.e., independent of whether or not the handle assembly  76  is linked or delinked from disconnector shaft  80  (see again  FIG. 4 )). 
   With auxiliary contacts that are directly controlled by handle assembly manipulation, various useful control circuits can be configured. For example, referring still to  FIG. 15 , even if end  160  of extension member  100  is decoupled from shaft  80  with breaker  416  switches open, one of the handle assembly auxiliary contacts  114  may be provided in series with contactor coil  444  so that, when handle assembly  76  is manipulated into the ON position, handle assembly  76  directly closes contact  114  thereby providing power to coil  444  despite the fact that breaker  416  remains open. When power is provided to coil  444 , contactor contacts  456 ,  450  and  442  transition to their closed states. When contactor  418  transitions between the closed and open states, a distinctive noise recognizable as a transitioning contactor can be heard which can be used to verify that contactor  418  is operating properly. Similarly, handle assembly  76  can be manipulated into the OFF position thereby causing contactor  114  to open cutting off power to coil  444  and transitioning contactor  418  between the closed and open states. 
   As another example, in embodiments that include both handle mounted auxiliary contacts and handle mounted lights, one or more auxiliary contacts that change state as a function of handle position, may be linked to one or more of the handle assembly lights so that handle positions are easily visually detectable from various distances. For instance, referring to  FIG. 5 , where a handle assembly  76  includes ON and OFF positions (see  216  and  212 , respectively), one of the contacts  114  may be configured and positioned to be activated when handle assembly  76  is in the OFF position and may be wired in series with a red emitting OFF light  140 . Similarly, a second handle assembly contact  112  may be configured and positioned to be activated when handle assembly  76  is in the ON position and may be wired in series with a green emitting ON light  142 . In the above example, the different colored light emissions will be recognizable from extended distances to indicate handle and breaker block status. Other handle assembly positions (e.g., TRIP—see  214 , RESET—see  210 , etc.) may also be annunciated via handle lights. 
   As one other example, where power is provided to coil  444  through a circuit that does not include handle assembly contacts (e.g., through a separate start-emergency stop button assembly), one or more of the handle assembly lights may be linked in series with coil  444  to indicate whether or not current is passing through the coil. Many other circuits are contemplated wherein auxiliary contacts  108 ,  110 ,  112 , and  114  are positioned in series with other assembly components (e.g., trip indicating lights, on/off lights, etc.) and, indeed, where at least one and, in many cases, more than one of the auxiliary contacts may not be linked to other block components. 
   Here it should be noted that, while some inventive embodiments may include both handle assembly lights as well as handle assembly auxiliary contacts, at least some embodiments will include lights and no handle assembly contacts while others will include handle assembly contacts and no handle assembly lights. In cases where the handle assembly does not include lights, the handle assembly contacts may be used in conjunction with other light devices mounted to cabinet door  72  or otherwise to communicate states/positions. Similarly, in cases where the handle assembly does not include auxiliary contacts, the handle assembly lights may be used in conjunction with other contacts in block  70  to indicate states. 
   Referring to  FIGS. 5–11 , handle assembly  76  includes a plurality of components arranged about an assembly axis  89 . The assembly components include a handle member  90 , a locking member  92 , an intermediate member  94 , a handle base member  96 , an extension member  100 , a light module  98 , a cam member  102 , a mounting member  104 , a coupling member in the form of a single nut  106  and first through fourth auxiliary contacts  108 ,  110 ,  112  and  114 , respectively. 
   Many of the handle assembly components to be described herein already have relatively complex mechanical structure which operates to facilitate various functions and which is generally well known in the art. Because much of the component structure is well known, much of the detailed structure of the components will not be described in detail. For instance, various structural aspects of handle member  90 , locking member  92 , intermediate member  94 , extension member  100  and base member  96  cooperate to limit movement of handle member  90  to a small number (e.g., 2–4) of positions such as ON and OFF positions and to allow locking member  92  to be positioned so as to lock handle member  90  in the OFF position. The structure that limits handle movement and facilitates locking is known and hence will not be described in detail. 
   Referring to  FIGS. 3–11 , handle member  90  includes a round disk shaped member  122  and a grip member  120  that is integrally formed with disk member  122  and extends to one side thereof. Grip member  120  forms one pointed end  121  and an opposite generally rounded end  123 . Pointed end  121  aligns with indicia (e.g., ON, OFF, TRIP, etc.) on a front surface  124  of base member  96  to indicate handle position. A slot shaped channel  125  is formed in disk member  122  and grip member  120  and a front surface  117  of grip member  120  forms a recess  113  such that slot  125  opens into recess  113 . 
   Locking member  92  is generally a flat rigid member having a receivable components  126  that, as its label implies, is received within channel  125  formed by handle member  90  and that is accessible within recess  113  when received in slot  125 . Receivable component  126  forms an aperture  127  that extends therethrough. At the proximal end of component  126 , extension members  129  and  131  extend laterally in opposite directions. Extension members  129  and  131  limit the extent to which locking member  92  and, more specifically, component  126 , is received within slot channel  125 . A spring (not illustrated) is provided between extension members  129  and  131  and oppositely facing surfaces of member  90  thereby biasing component  126  into a recessed position with respect to handle member  90 . As well known in the art, this spring force can be overcome by gripping the portion of member  126  that is accessible through recess  113  and pulling member  126  against the force of the spring until aperture  127  is observable within recess  113 . When aperture  127  is observable, a padlock or the like can be used to lock member  92  in the extended position. 
   Although not described here in detail, the structure of the handle assembly components is such that locking member  92  can only be pulled to its locking position when handle member  90  is in an OFF position and cannot be pulled into its locking position when handle  90  is in an ON position. In addition, the assembly component structures are such that, when locking member  92  is in its extended and locking positions, handle member  90  cannot be rotated from the OFF position (hence the label “locking member”) to the ON or any other position. 
   Intermediate member  94  includes a slot end  97  and a distal extending end  95 . Slot end  97  is formed to receive the portion of locking member  92  opposite component  126  and to enable sliding motion thereof along the assembly axis  89 . Distal end  95  extends opposite slot end  97 . 
   Referring to  FIGS. 7 through 10 , extension member  100  includes a proximal end  161  and a distal end  160 . Proximal end  161  receives end  95  of intermediate member  94  and links thereto in a manner known in the art. Proximal end  161  forms a flange  87  that extends laterally to a greater radius than other parts of member  100 . Distal end  160  includes an external surface that is at least in part threaded. Intermediate flange  87  and the threaded surface proximate end  160 , member  100  forms two laterally extending ribs  163  and  165  that extend in opposite directions laterally from the main section of member  100 . Ribs  163  and  165  are provided to lock with recesses  179  and  186  in cam member  102  to be described in greater detail below. 
   Base member  96  is a rigid generally rectilinear member having a front surface  124  and an oppositely facing rear surface  134 . Member  96  forms a central circular opening generally identified by numeral  128  and forms various structural components within opening  128  that operate with mechanical features of locking member  92 , intermediate member  94  and extension member  100  to restrict handle  90  movement to only certain positions and to facilitate the locking functionality described above. In at least some embodiments of the present invention, as best illustrated in  FIG. 5 , indicia is provided on front surface  124  that is juxtaposed with respect to structure  130  in opening  128  such that the indicia is aligned with pointed end  121  of handle member  90  when handle assembly  76  is in a position associated with the specific indicia. For instance, exemplary indicia in  FIG. 5  include “OFF” indication  212  and “ON” indication  216 . When pointed end  121  of member  90  is aligned with ON indication  216 , handle assembly  76  is in an ON position such that, if shaft  80  is linked thereto via distal end  160  of extension member  100 , shaft  80  is likewise in an ON position. Similarly, when pointed end  121  is aligned with OFF indication  212  and shaft  80  is linked to extension member  100  for rotation therewith, shaft  80  is likewise in the OFF position. 
   Light module  98  includes a generally square plate member  138  that has a rib  136  around its circumference and that forms a central circular hole  150  sized to pass distal end  160  of extension member  100 . Rib  136  and plate  138  generally form a cavity  137  for receiving the rear surface  134  of base member  96 . Lights  140 ,  142 ,  144  and  146  are provided in rib  136 . The lights may take any of several different forms including incandescent light bulbs, LEDs, etc., and may be provided in any of several different arrangements including a single light, multiple lights along one edge of rib  136 , lights along opposite edges of rib  136 , etc. In the illustrated embodiment a separate light is provided in each of the four rib edges. While each of the lights may emit the same color light, in at least some embodiments it is contemplated that each light may emit a different color light (e.g., red, green, yellow, blue, etc.) where each color would be associated or associable with a different handle assembly state or a different state of the breaker assembly  70 . 
   Referring to  FIG. 8  and also to  FIG. 10 , an eight pin electrical port  158  is formed in a rear surface  152  just below opening  150 . A separate pair of electrical conductors or leads  230  (only one shown) extends from port  158  to each of lights  140 ,  142 ,  144  and  146 . In the illustrated embodiment leads  230  are potted within plate member  138  although other accommodating configurations are contemplated. Referring still to  FIG. 8 , two aligning pegs  154  and  156  extend perpendicular to rear surface  152  of light module  98 . Pegs  154  and  156  are received within holes formed in door  72  to facilitate alignment of components on the inside and the outside of the door  72 . 
   Referring to  FIGS. 7 through 11 , door  72  forms an opening  170  through which distal end  160  of extension member  100  extends. An eight pin male connector (see  196  in  FIG. 7 ) that extends from mounting member  104  also extends through opening  170 . Aligning holes  211  are provided on opposite sides of opening  170  which receive pegs  154  and  156  to align handle assembly components on both internal door surface  84  and external door surface  82 . 
   Referring still to  FIGS. 7 and 8  and also to  FIG. 12 , cam member  102  is a disk shaped member forming a central circular opening  183 . Two laterally extending recesses  184  and  186  are formed in opening  183  that are generally of small arc and that open in opposite directions from recess  183 . Recesses  184  and  186  are sized, dimensioned and juxtaposed such that when distal end  160  of extension member  100  extends through opening  183 , ribs  163  and  165  are journalled within recesses  184  and  185 , respectively, so that, when extension member  100  is rotated about assembly axis  89 , cam member  102  similarly rotates. 
   A radial slot  185  is formed to one side of opening  183  to pass male connector  196  that extend from mounting member  104  so that the distal end of the connector  196  can be linked to port  158  in the rear surface  152  of light module  98 . Slot  185  is dimensioned so that connector  196  passes therethrough independent of the rotational position of cam member  102  with respect to assembly axis  89 . Thus, in at least some embodiments, slot  185  will extend about an arc of 140°–150°. 
   Cam  102  includes two cam extensions  180  and  182  that extend from a rear cam surface  179 . Each extension  180  and  182  extends from an edge of cam  102  toward opening  183  and are radially positioned with respect to recesses  184  and  186  such that the cam extensions  180  and  182  contact and depress activation members (e.g.,  260  and  262  in  FIG. 7 ) on contacts  108 ,  110 ,  112  and  114  when the cam  102  is in specific positions. The cooperative activity between extensions  180  and  182  and the activation members will be described in more detail below. 
   Mounting member  104  includes a generally square plate member  194  and a rib  192  that extends around the edge of plate member  194  so that plate member  194  and rib  192  form a shallow cavity  195 . Plate  194  includes front and rear surfaces  194  and  198 , respectively, and forms a central circular opening  190  suitably dimensioned to pass the threaded end of extension member  100 . Plate  194  also forms four square shaped apertures  210 ,  212 ,  214  and  216  for passing contact activation buttons or members (e.g.,  260 ,  262 , etc.), a separate pair of the apertures  210 ,  212 ,  214  and  216  formed on each side of assembly axis  89 . 
   Referring to  FIGS. 7 and 10 , a male electrical connector  196  extend from plate  194  within cavity  195 . Connector  196  is positioned such that the connector extend through cam slot  185  when cam  102  and mounting member are adjacent and aligned with axis  89 . Connector  196  has a length dimension such that distal end thereof is receivable within port  158  (see  FIGS. 8 and 10 ) upon assembly of handle assembly  76 . 
   Referring to  FIGS. 6 and 10 , four pairs of connection terminals  600 ,  602 ,  604  and  606  are provided near the lower and upper edges of rear surface  198  of mounting member  104 . The terminals are electrically linked with 8-pin male connector  196  (see also  FIG. 7 ) via leads  232 . In the illustrated embodiment, leads  232  are potted within plate  198  although other accommodating configurations are contemplated. Referring also to  FIGS. 7 and 8 , when connector  196  is received in port  158 , lights  140 ,  142 ,  144  and  146  are electrically linked to terminal pairs  600 ,  602 ,  604  and  606 , respectively. 
   Referring to  FIGS. 7 through 11 , nut  106  forms a threaded aperture  202  dimensioned to be threadably receivable on distal end  160  of extension member  100 . Each of contacts  108 ,  110 ,  112  and  114  is a normally closed contact although in some embodiments one or more normally open contacts may be provided. Each of contacts  108 ,  110 ,  112  and  114  is mechanically activated to change state by depression of an associated push button type activation member. For instance, contact  108  includes a push button  260  that, when pressed, causes contact  108  to close and, when released, allows contact  108  to again open. Activation members for contacts  110 ,  112 , and  114  are identified by numerals  262 ,  264  and  266 , respectively. The activation members have length dimensions such that they extend through apertures  210 ,  212 ,  214  and  216  formed in plate  198  and into cavity  195  (see again  FIG. 7 ) when the contacts are mounted to rear surface  198 . Referring again to  FIG. 12 , when one of the cam extensions  180  or  182  is aligned with one of the activation members  210 ,  212 ,  214  or  216 , the cam extension contacts and depresses or activates the activation member thereby causing the associated contact to transition to the closed state. 
   Referring again to  FIGS. 4 ,  5  and  15 , the handle assembly components are configured such that, when assembly  76  is linked to shaft  80 , handle member  90  is rotatable through 90° of rotation between an ON position in which circuit breaker switches  425 ,  426  and  458  are closed and an OFF position in which switches  425 ,  426  and  458  are open. In addition, when breaker  416  is tripped and automatically opened, handle member  90  is rotated 30° counter-clockwise from the ON position. After the breaker trips, an operator is required to reset the breaker assembly prior to moving handle 90° to the ON position by rotating handle approximately 80° counter-clockwise (i.e., approximately 20° past the OFF handle position) into the RESET position. 
   In the illustrated embodiment, referring also to  FIGS. 7 ,  8  and  12 , when cam  102  is journalled to extension member  100  for rotation therewith and the other assembly  76  components are assembled, cam extension  180  is aligned with contact activation member  264  (the activation members illustrated in  FIG. 12  as cross-hatched squares) when handle  90  is in the OFF position. When handle member  90  is rotated counter-clockwise to the RESET position, cam extension  182  contacts and activates activation member  262 . 
   In  FIG. 12 , the rear surface of cam member  102  is illustrated. When viewing the rear surface of cam  102  the frame of reference is opposite that of handle assembly  76  as viewed in  FIG. 5  (i.e., when handle member  90  is rotated counter-clockwise in  FIG. 5 , the rear surface of cam  102  in  FIG. 12  rotates clockwise and vice versa). Thus, when handle member  90  is rotated counter-clockwise 20° to the RESET position in  FIG. 5 , cam member  102  rotates 20° clockwise so that extension  182  is aligned with arrow  506  and activates activation button  262 . Similarly, when handle  90  is rotated to the ON position, cam extension  180  is aligned with arrow  504  and activates activation member  266  and when handle member  90  is in the TRIP position, cam  182  is aligned with arrow  508  and activates activation member  260 . 
   Referring again to  FIGS. 7 through 12 , handle assembly  76  is assembled about assembly axis  89  as follows. Extension component  126  is received within slot  125  of handle member  90  and the opposite end of locking member  92  is received by the slot end  97  of intermediate member  94 . End  95  of intermediate member  94  is received by end  161  of extension member  100 . End  160  of extension member  100  is received through opening  128  of base member  96 . Base member  96  is aligned with cavity  137  formed by light module  98  and rear surface  134  of base member  96  is received within cavity  137 . Light module  98  is aligned with opening  170  and such that pegs  154  and  156  are aligned with alignment apertures  211  and module  98  is held against the external surface  82  of door  72 . 
   Continuing, with distal end  160  of extension member  100  extending through opening  170 , cam member  102  is aligned with end  160  and slid thereon such that ribs  163  and  165  (see again  FIG. 12 ) are journalled within recesses  184  and  186 , respectively. Mounting member  104  is positioned such that the distal end  160  of extension member  100  is aligned with opening  190  and is moved toward internal surface  84  of door  72  such that end  160  passes through opening  190 . Here, distal ends of pegs  154  and  156  are receivable within corners formed by rib  192  and therefore help align mounting member  104  with module  154  despite the fact that those components are on opposite sides of door  72 . When module  104  is properly positioned, male connector  196  extends through slot  185  (see again  FIG. 12 ) and are received within port  158  such that terminals  600 ,  602 ,  604  and  606  are electrically linked to light  140 ,  142 ,  144  and  146  as described above. 
   Nut  106  is threadably received on distal end  160  of extension member  100  and bears against the rear surface  198  of member  104  thereby holding all of the handle assembly components together. Contacts  108 ,  110 ,  112  and  114  are mounted to rear surface  198  of mounting member  104  such that activation members (i.e., the push buttons)  260 ,  262 ,  264  and  266  extend through apertures  214 ,  216 ,  210  and  212  in mounting member  104 . 
   While the assembly components described above are described as being assembled in a certain order, it should be appreciated that some of the components may be pre-assembled into subassemblies prior to final assembly. For instance, contacts  108 ,  110 ,  112  and  114  would likely be pre-mounted to member  104  prior to final assembly. In addition, members  90 ,  92 ,  94 ,  100  and  96  and module  98  may be pre-assembled prior to final assembly. Moreover, module  98  may be separate from the pre-assembled subassembly including members  90 ,  92 ,  94 ,  100  and  96 . 
   Importantly, with the assembly described above, the components can be electrically linked in various ways to perform various functions. For instance, any of the lights  140 ,  142 ,  144  and  146  may be linked in series with any contacts (none illustrated) located within cabinet  71  to visually annunciate the status of the contact during system operation. In addition, any of the lights or a subset thereof may be linked in series with any of the handle mounted auxiliary contacts  108 ,  110 ,  112  or  114  to visually annunciate (i.e., illuminate an associated light) the status of the handle assembly  76 . For instance, referring again to  FIGS. 4 ,  6  and  15 , contact  112  may be linked in series with a low voltage power source and light  144  via terminal pair  604 . Here, because contact  112  is normally open, when handle member  90  and hence cam  102  are in the OFF position (see cam  102  position in  FIG. 12 ), contact  112  provides power to light  144  and visually annunciates that handle  90  is in the OFF position. When handle member  90  and cam  102  are rotated from the OFF position, cam extension  180  releases member  264  and contact  112  opens to turn off light  144 . 
   Referring still to  FIGS. 5 ,  6  and  15 , contact  114  may be linked in series with light  140  via terminal pair  600 . Here referring also to  FIG. 12 , when cam  102  and handle member  90  are rotated to the ON position, cam extension  180  activates member  266  (see arrow  504 ) to close contact  114  and illuminate light  140  to indicate the ON handle position. Similarly, contact  110  may be linked in series with light  146  via terminal pair  606  so that when cam  102  and handle  90  are rotated to the RESET position, cam extension  182  activates member  262  (see arrow  506 ) to close contact  110  and illuminate light  146  indicating the RESET handle position. Moreover, contact  108  may be linked in series with light  142  via terminal pair  602  so that when cam  102  and handle member  90  are in the tripped position, cam extension  182  activates member  260  (see arrow  508 ) to close contact  108  and illuminate light  142  to indicate the handle TRIP position. 
   In the above example, while each of the contacts  108 ,  110 ,  112  and  114  may be linked to separate lights  140 ,  142 ,  144  and  146 , in at least some cases only a subset of the linkages maybe made. For instance in some cases only ON and OFF lights  140  and  144  may be linked to contacts. Where only a subset of the contacts are linked to lights, the other contacts may be linked to other components within cabinet  71 . In addition, in some cases two or more of the handle lights may be linked in series with a single one of the contacts. For instance, contact  108  may be linked in series with all of lights  140 ,  142 ,  144  and  146  so that all of the lights are illuminated when a TRIP condition occurs. 
   In at least some embodiments it is contemplated that the contacts  108 ,  110 ,  112  and  114  may be pre-wired to specific terminal pairs or indeed directly to specific pins on connector  196  so that the contact functions cannot be altered. Here, versatility in assembly  76  functionality may still be achievable by providing two or more swappable cam members  102  where the different cam members have different cam extension characteristics. For instance, while a first cam member may have the characteristics illustrated in  FIG. 12 , a second cam member (not illustrated) may only include cam extension  180  and may not include extension  182 . Here, when the first cam  102  is employed the handle assembly would be capable of illuminating a different handle light for each of the ON, OFF, TRIP, and RESET positions. However, when the second cam is employed the handle assembly would only be capable of illuminating separate handle lights for the ON and OFF positions. 
   In other embodiments a single cam member may be securable to extension member  100  in two or more relative juxtapositions where the cam extension configuration operates differently in the different juxtapositions. For instance, in  FIG. 13  a different cam member  300  is illustrated which includes only a single cam extension  330  but that forms two pairs of recesses in a central opening  332 . The first pair  322  and  323  are arranged with respect to cam extension  330  such that, when ribs  163  and  165  on member  100  are journalled therein, cam extension  330  operates in a fashion similar to that described above with respect to  FIG. 12  to activate members  264  and  266  when the handle member  90  is in the OFF (illustrated) and ON (see arrow  289 ) positions, respectively. In addition, when ribs  163  and  165  are journalled in recesses  322  and  323 , no cam extensions interact with activation members  260  and  262  in any of the handle positions. 
   The second recess pair  320  and  321  are angularly offset from pair  322  and  323  and are juxtaposed with respect to cam extension  330  such that when ribs  163  and  165  are journalled in recesses  322  and  323 , respectively, as illustrated in  FIG. 14 , cam extension  330  is aligned between activation members  260  and  262 . Here, cam extension  330  activates member  260  when handle member  90  is in the TRIP position (i.e., when extension  330  is aligned with arrow  352 ) and activates member  262  when handle member  90  is in the RESET (i.e., when extension  330  is aligned with arrow  350 ). Here, when ribs  163  and  165  are journalled in recesses  320  and  321 , no cam extensions interact with activation members  264  and  266  in any of the handle positions. 
   At this point it should be appreciated that a unique exemplary hardware configuration has been described that includes several cooperating components. However, it should also be understood that other similar configurations are contemplated. For instance, while the assembly  76  above includes four contacts  108 ,  110 ,  112  and  114 , it should be appreciated that assemblies with fewer and greater numbers of contacts are contemplated. Also, in some cases all or a subset of the handle assembly contacts may be provided outside cabinet  71 . Moreover, more or less than four lights may be included in the handle assembly  76 . In addition, in some cases the light module  98  may be replaced with lights on the handle member  90  or in the base member  96 . 
   Furthermore, embodiments including more than two swappable cam members are contemplated where each of the cam members has different camming characteristics such that an extremely versatile handle assembly results. In addition, while an embodiment having a swappable cam is described above, other embodiments are contemplated where mounting members  96  are swappable to provide similar variable functionality by altering the relative juxtapositions of cam extensions and the contact activation members. 
   Moreover, embodiments are also contemplated where a single mounting member  96  and associated contacts may be positionable in more than one relative juxtaposition with respect to the base member  96  so as to alter the juxtapositions of contact activation members and the cam extensions and hence alter functionality. In addition, in at least some embodiments, the cam member may be eliminated and the cam extension(s) may be provided as an integral part(s) of the extension member  100 . In cases where the handle assembly does not include auxiliary contacts, the cam member  102  may be completely eliminated. 
   From the foregoing, it will be observed that numerous modifications and variations can be effected without departing from the true spirit and scope of the novel concept of the present invention. It will be appreciated that the present disclosure is intended as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims. 
   To apprise the public of the scope of this invention, the following claims are made: