Abstract:
A electronic motor protection system is shown having a power supply (12) usable with multivoltage supplies and providing protection from over-temperature conditions caused by various fault conditions. The system also has optional features of a time delay (20) for re-energization and for low voltage protection (22). The system is mounted on a circuit board and encased in potting material which also locks two housing parts together (30, 34). A miswiring feature is also provided to prevent connecting line voltage to the control circuit or sensor terminals.

Description:
This is a continuation-in-part of Ser. No. 08/260,627 filed Jun. 16, 1994 now abandoned in favor of continuation application Ser. No. 08/444,446; Ser. No. 08/260,627 being a continuation application of Ser. No. 07/943,254 filed Sep. 10, 1992, now abandoned. 
    
    
     This invention relates generally to protection apparatus for electric motors and more specifically to electronic protection systems particularly suitable for compressor motors. 
     Systems for protecting dynamoelectric machines from over-temperature conditions comprising one or more thermal sensors, such as positive temperature coefficient (PTC) of resistivity sensors, disposed in heat transfer relationship with the windings of the motor are well known in the prior art. It is also well known to add other protective functions to such systems which will protect various apparatus from the occurrence of additional conditions in an economical and efficient manner. For example, once the supply of power to a load has been interrupted, either through the sensing of an over-temperature condition by the PTC sensors and concomitant tripping of the protection circuit, the opening of a contactor or for any other reason, it is undesirable to permit reapplication of power to certain loads, such as air conditioner compressors, until after a certain period of time has elapsed thereby permitting the load to return to a condition suitable for re-energization. In the case of compressors a short time delay allows equalization of pressure in the compressor so that less starting torque is required. 
     A system which accomplishes the above functions in an effective manner as well as providing additional protective features such as oil pressure protection to ensure that the system is not operated when oil pressure falls below a safe value for more than a selected time interval and a low voltage feature to avoid the possibility of causing contact chattering or having one phase of a multiphase motor drop out which would cause overworking of the remaining phases is shown and described in U.S. Pat. No. 4,281,358 assigned to the assignee of the present invention. 
     In the system described in the referenced patent the protection system has a power supply including a conventional transformer to convert outside supply voltage to a selected lower voltage suitable for operation of the control circuit. In that patent the control circuit utilizes a 24 volt supply so that separate transformer means, or at least a transformer with selected taps has to be utilized with different line voltage supplies. This results in having to provide different models of the protection system for different line voltage applications. 
     It is an object of the invention to provide an electronic motor protector providing multifunction protection which can be used with a plurality of different line voltages. Another object is the provision of an inexpensive yet reliable motor protection system. Still another object is the provision of such a system which is compact in size and light in weight. 
     Briefly, in accordance with the invention, a solid state power supply comprising an integrated circuit having a first switching pre-regulator section and a second voltage regulator section is used to provide a selected DC voltage. The switching pre-regulator conducts for a portion of the positive half of the AC line cycle which is used to charge a capacitor which in turn is coupled to the voltage regulator to provide a first level of DC voltage. An inhibit capacitor is coupled to the pre-regulator and is adapted to turn off the pre-regulator on the occurrence of transients exceeding a selected dv/dt rating. According to the invention the first level of DC voltage is used to directly drive a relay to control energization of the motor contactor. The first level of DC voltage is in turn stepped down by a limiting resistor and a zener diode to provide a second level of DC voltage for energizing the control circuitry. 
     The control circuitry comprises a plurality of cascaded operational amplifiers in the form of comparator sections providing a single channel including an over-temperature protection section in which one or more PTC thermal sensors are coupled to the inverting input of a first comparator. The output of the first comparator is coupled to a buffer comparator which in turn is coupled to the base of a transistor serially connected to the relay coil. The output of the first comparator is also optionally connected to a time delay comparator whose output is coupled back to the inverting input of the first comparator. The output of the first comparator is also optionally coupled to the output of a low voltage comparator. 
     According to a feature of the invention the protection system is mounted on a circuit board received in the bottom half of a housing which is encased with potting material to provide vibration insensitivity, environment protection and to meet agency standard spacing requirements. The top half of the housing has a plurality of ribbed depending skirts adapted to extend into the potting material to lock the housing parts together. According to another feature of the invention the input blade line terminals of the system are configured smaller than the sensor or output terminals to obviate any possibility of miswiring by putting line voltage across the control circuit or sensor circuits. 
     According to an alternate embodiment, nuisance tripping of the pre-regulator section of the integrated circuit power supply caused by certain conditions common in industrial environments is avoided by eliminating the inhibit capacitor which had been tied to ground and instead using a diode and capacitor combination tied to the high side of line voltage. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Other objects, advantages and details of the novel and improved protection apparatus of the invention appear in the following detailed description of the preferred embodiment, the detailed description referring to the drawings in which: 
     FIG. 1 is a schematic circuit diagram of the protection apparatus made in accordance with the invention; 
     FIG. 2 is a voltage vs time graph showing line voltage and voltage at the IC pin of the switching pre-regulator; 
     FIG. 3 is a blown apart perspective of the upper and lower housings of the protection apparatus made in accordance with the invention; 
     FIG. 4 is a cross sectional view taken on line 4--4 of FIG. 3; 
     FIG. 5 is a top view of an assembled protection apparatus shown in FIG. 3. 
     FIG. 6 is a schematic circuit diagram of a modified power supply section of the protection apparatus made in accordance with a modified embodiment of the invention; and 
     FIG. 7 is a functional diagram of the power supply integrated circuit used in FIGS. 1 and 6. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     With reference to FIG. 1, protection apparatus 10 made in accordance with the invention comprises a power supply section 12, over-temperature protection section 14, output circuit 18, time delay section 20 and low voltage cut-out section 22. Section 14 includes operational amplifier comparators 1 and 4 and sections 20 and 22 include operational amplifier comparators 2 and 3 respectively, each comparator having an NPN output BJT transistor (open collector). During steady state operating conditions the output transistor of comparator 1 is off, the output transistor of comparators 4 and 2 are on, and the output transistor of comparator 3 is off. As will be explained in detail below, when an over-temperature condition occurs it will cause the output transistor of comparator 1 to turn on and the output transistor of comparators 4 and 2 to turn off (comparator 3 still being off). When low voltage conditions occur the output transistor of comparators 1, 4 and 2 are off and the output transistor of comparator 3 turns on. 
     With regard to specific sections of circuit 10, power supply section 12 comprises a fuse F1 connected to the AC high, terminal T2 as a safety feature so that in the event of a short circuit the apparatus will fail with an open circuit. A surge suppressor varistor MOV1 is coupled across the AC high terminal T2 and AC return terminal T1 to clamp high frequency and high energy transients such as lightning surges. Resistors R1, R2 and capacitor C1 connected across the AC lines serve as a low pass filter to filter high frequency noise and line spikes. Additionally, resistors R1, R2 serve as current limiting devices for the SCR based pre-regulator to be discussed below. 
     Circuit section 10 includes a single chip power supply, integrated circuit 24. IC 24 has eight pins only seven of which are utilized, pin 7 being unconnected. As seen in FIG. 7, IC 24 comprises two sections, a switching pre-regulator 24a and a linear post or voltage-regulator 24b. Pin 8 serves as an input pin and is connected through current limiting resistors R1, R2 to T2, an AC high line and internally to internal switch 24c which connects pin 8 with pin 2. Pin 2 is also connected to the input of voltage regulator section 24b. An external energy storage capacitor C2 has one side connected to pin 2 and its opposite side connected to the AC return T1. Pin 1, connected internally to pin 3, is also connected to AC return T1. When the input voltage goes positive the internal switch 24c comprising a diode DA1 connected to the main electrodes of an SCR SA1 allows current to flow charging capacitor C2. Switch 24c also comprises an SCR SA2 whose main electrodes are connected to the gate of SCR SA1 and to pin 1. SCR SA2 has a second anode connected to an internal zener diode/rectifier diode stack, voltage reference circuit 24d, which is used to be compared with the output voltage at pin 6 during the charging of capacitor C2. When the voltage on capacitor C2 reaches a level of the output voltage plus the voltage across reference circuit 24d the switch 24c is turned off and charging of capacitor C2 stops. 
     Voltage regulator section 24b takes current from capacitor C2 to provide an output voltage on pin 6 which is set by feedback to sense pin 5 which is connected internally in IC 24 to amplifier stage 24e and in turn coupled to output pin 6. The output will rise to a voltage level necessary to keep sense pin 5 at 5 volts and may be adjusted above the 5 volt reference by placing a selected resistance such as resistor R4 shown in FIG. 1, or zener diode, between pins 5 and 6 (an additional 1 volt is provided for each one thousand ohms so that resistor R4 of 19 Kohms provides a 24 Vdc output on line 26 used in the preferred embodiments for relay coil K1 and associated contacts M1, M2. The same output would be accomplished via a 19 volt zener diode). 
     Pin 4 is coupled internally in IC 24 to voltage reference circuit 24d and when shorted to T1 will turn switch 24c off. More specifically, pin 4 is connected to a second anode of SCR SA2 providing a safety feature keeping switch 24c off during large dv/dt transients by means of connecting an inhibit capacitor C3 between pin 4 and pin 1 (T1-AC return) so that when subjected to large dv/dt transients the effective impedance of C3 becomes negligible shunting current away from the gate of SCR SA1 to the AC return line (T1). 
     With reference to FIG. 2 which shows the voltage vs time curve at a of line voltage, typically 60 Hertz frequency and at b the waveform as seen at pin 8, the resistance level of current limiting resistors R1, R2 is preferably chosen so that the SCR conduction of the pre-regulator section is typically in the order of 1-2 milliseconds for a 60 Hertz frequency occurring on the positive half of the AC cycle. Limiting conduction of the SCR of the pre-regulator section is particularly advantageous in an industrial environment subject to noisy lines in order to ensure that the safe operating range of SCR SA1 will not be exceeded. 
     A lower voltage, i.e., 12 volts, suitable for operation of the control circuit, to be explained infra, is provided by suitable means such as a dropping resistor R28 serially connected to a 12 volt zener diode ZD1 connected between the output of IC 24 and ground. Power supply section 12 also includes a snubber capacitor C4 connected between the low voltage output at the junction of resistor R28 and diode ZD1 and ground. Alternatively, the low voltage power supply could be provided by a voltage divider comprising two resistors, if desired. 
     Over-temperature protection section 14 comprises a comparator 1 having its inverting input connected, through diode D1, resistor R29 and capacitor C9 to the junction of a reference resistor R5 and a PTC resistor which are connected between control circuit supply voltage 28 and ground. Diode D1 serves to isolate resistor R5 and the PTC from any feedback from the supply rail 28 through resistors R16, R17 when the output transistor of comparator 2 is off and the inverting input is tied to the 12 volt rail. The non-inverting input of the comparator 1 is connected to the junction of voltage divider resistors R6, R7 connected between line 28 and ground to establish a reference voltage. Feedback resistor R8 is connected between the output of comparator 1 and the non-inverting input. Capacitor C9 is connected between the inverting output of comparator 1 and ground. The RC network of resistor R29 and capacitor C9 snubs down noise transients on the sensor input thereby preventing nuisance tripping. 
     The output of comparator 1 is connected to the junction of a voltage divider in a buffer circuit portion comprising resistors R9, R10 and the junction in turn is connected to the inverting input of comparator 4. The non-inverting input is connected to the junction of a voltage divider comprising resistors R11, R12. Feedback resistor R13, providing hysteresis which in turn provides a clear demarcation for switching of comparator 4 and avoiding contact chatter, is connected between the output of comparator 4 and the non-inverting input. The output of comparator 4 is connected to the output voltage line 26 of IC 24 through resistors R14, R15 in output circuit 18. The emitter, collector terminals of PNP transistor Q1 are serially connected between supply line 26 and relay coil K1 which in turn is connected to ground. The base of the transistor is connected to the junction of resistors R14, R15. Diode D3 is coupled across relay coil K1 to prevent back EMF, thereby protecting transistor Q1. 
     As stated supra, a fixed voltage reference provided by voltage divider R6, R7 establishes a threshold level at the non-inverting input of comparator 1. The variable voltage provided by the PTC sensor comprises the variable voltage at the inverting terminal of comparator 1 which varies according to the change in the resistance of the PTC dependent on changes in temperature of the PTC. When the voltage at the inverting terminal exceeds that of the non-inverting terminal the output NPN transistor of comparator 1 is biased on thereby sinking current to ground. This results in the reference voltage at the non-inverting input of comparator 4 being greater than the voltage at the inverting input of comparator 4 resulting in the output transistor of comparator 4 to be biased off preventing current flow to ground for transistor Q1 and concomitantly de-energizing the relay coil K1 opening contacts M1, M2 and, in turn, the motor. Feedback resistor R8 provides hysteresis to prevent transistor Q1 from being biased on until the PTC element has cooled to its normal operating resistance level at which time the circuit will reset and permit energization of coil K1, contacts M1, M2 and the motor. 
     Time delay section 20 is an optional feature comprising comparator 2 whose non-inverting input is connected through resistor R21 to a point between resistor R19 and diode D4 to the junction of resistors R18 and R20. Resistor R18 is connected to the supply rail 28 while resistor R20 is connected to the output of comparator 1. The inverting input of comparator 2 is connected to the junction of resistors R18 and R20. The RC network comprising capacitor C6 coupled around resistor R19 provides the selected time delay. A resistance value of 1.1 MEG. ohms for resistor R19 provides a four minute delay using 100 uf for capacitor C6. By using a resistance value of 500K ohms for R19 a two minute delay is provided. Resistor R21 prevents discharge current from capacitor C6 from going back into the non-inverting terminal. The output of comparator 2 is connected to the junction of resistors R16, R17 which are connected between supply line 28 and the inverting input of comparator 1. During steady state operation of a motor the input voltage at the inverting terminal of comparator 2 exceeds that of the non-inverting terminal due to the voltage drop of diode D4 with the output transistor biased on. When the module trips due to an over-temperature condition, or the like, the output transistor of comparator 1 is biased on sinking current from resistor R20 to ground thereby lowering potential between voltage divider R18, R20 so that voltage at non-inverting terminal of comparator 2 exceeds that of the inverting terminal and the output transistor of comparator 2 is biased off. Since the output of comparator 2 is tied to the inverting input of comparator 1 it keeps the inverting input of comparator 1 tied to the supply rail 28 until capacitor C6, discharging through resistor R19, decreases to a value lower than the voltage at the inverting input of comparator 2 and the circuit is then reset. Diode D4 prevents any current from capacitor C6 back feeding to the supply rail. 
     Low voltage cut-out circuit section 22 is another optional feature and it comprises comparator 3 whose non-inverting input terminal is connected to the junction of resistors R25, R26 which are connected through diode D6 and resistor R27 between AC line voltage and ground with capacitor C8 coupled across resistors R25, R26. The inverting input terminal of comparator 3 is connected between resistor R23 and zener diode ZD2 connected between supply line 28 and ground to provide a reference voltage. The output of comparator 3 is connected to the output of comparator 1. Feedback resistor R22 and diode D5 are connected between the output of comparator 3 and the non-inverting input thereof. Resistor R22 provides hysteresis to avoid problems with the ripple voltage associated with charging of capacitor C8. When a motor is first energized resistor R22 and diode D5 are in parallel with resistor R26; however, once the peak of the ripple voltage charging capacitor C8 exceeds the reference voltage of zener diode ZD2 causing a change of state of comparator 3 resistor R22 is effectively removed with the voltage at the non-inverting input of comparator 3 going significantly higher, e.g., from approximately 3.2 V to approximately 5 V. Capacitor C7 is connected between the input terminals of comparator 3 to suppress any high frequency transients at the input terminals. 
     During normal operation the output transistor of comparator 3 is off and the potential of the inverting input of comparator 3 is less than the potential at the non-inverting input. When line voltage starts to decrease thereby decreasing the voltage at the non-inverting terminal below the preselected level thereby biasing the output transistor of comparator 3 on. Current flows from supply rail 28 and since the output transistor of comparator 1 is off the current flows to ground through output transistor of comparator 3. The inverting input of comparator 4 is than tied to ground making the positive or non-inverting input higher than the negative input turning off the output transistor of comparator 4, so that the base junction of transistor Q1 is no longer tied to ground. 
     When the time delay option is used if an over-temperature or low voltage condition is sensed a pre-programmed two or four minute delay will be activated preventing energization of the relay (and motor) even though the PTC sensor may have cooled to the reset temperature. 
     Preferably the time delay function is used whenever the low voltage function is used to prevent undesirable oscillation should the voltage hover near the designed cut-out value. In those cases where it is preferred not to employ these functions they can easily be shorted out using appropriate jumpers to tie the inputs of comparators 2 and 3 to ground and removing jumpers J1 and J2. 
     A circuit built in accordance with the invention has the following component values: 
     
         ______________________________________MOV1            270 V        R1 75 ohms 3 W - 5%C1              .10 uf (275 VAC)                        R3 2 ohms - 5%C2              470 uf       R4 19K ohms - 1%C3              150 pf       R5 2.67K ohms - 1%C4              4.7 uf (50 V)                        R6 75K ohms - 1%C5              .01 uf       R7 121K ohms - 1%C6              100 uf (25 V)                        R8 182K ohms - 1%C7              .01 uf       R9 5K ohms - 5%C8              4.7 uf (50 V)                        R10 5K ohms - 1%C9              .01 uf (50 V)                        R11 56K ohms - 5%IC 24           HV3-240E-9Harris Semiconductor Co.comparator 1                 R12 10K ohms - 5%comparator 2    LM2901       R13 270K ohms - 5%comparator 3    (Texas       R14 7K ohms - 5%           Instruments)comparator 4                 R15 27K ohms - 5%ZD1             12 V         R16 218K ohms - 5%ZD2             3.9 V        R17 330K ohms - 1%Q1                           R18 15K ohms - 1%(2N4403; NPN)D1 1N 4004                   R19 1.1M ohms - 1%D2 1N 4004                   R20 1.8K ohms - 1%D3 1N 4004                   R21 470K ohms - 5%                        R22 75K ohms - 1%D4 1N 4004                   R23 2.7K ohms - 5%D5 1N 4004                   R25 22K ohms - 1%D6 1N 4004                   R26 R Select ohms - 1%Relay           24 V         R27 169K - 1%           Omron G2R    R28 1K - 1%                        R29 150K - 1%                        PTC 1.0K BA Sensor                        (Texas Instruments)______________________________________ 
    
     In certain industrial applications the motor protection system is subjected to radiated and/or conductive noise transient conditions which can cause erratic operation of IC 24 and nuisance tripping by turning off internal switch 24c through inhibit capacitor C3 and in turn the entire system. With reference to FIG. 6 a modified embodiment of the invention is shown which prevents such nuisance tripping. As seen in the figure, the cathode of a diode D7 is connected to pin 4 with its anode connected to pin 1 and a capacitor C10 is connected between pins 4 and 8. When subjected to noise transient conditions the high impedance imposed on pin 4 by pull-up capacitor C10 and reversed biased diode D7 will prevent SCR&#39;s SA1 and SA2 from turning off thereby preventing them from functioning erratically during these adverse conditions and allowing them to function in a manner similar to normal mode operation. MOV1 and the front end filter network comprising resistors R31, R32 and R33 and capacitor C1 are increased in value relative to FIG. 1 to enhance filtering capability to reduce large dv/dt transients at pin 8 and prevent SCR SA1 of switch 24c from being damaged. 
     A circuit built in accordance with FIG. 6 has the following component values: 
     
         ______________________________________MOV1   275 V        R31     64.9 ohms                               3 w - 1%C1     .22 uf (250 V)               R32     64.9 ohms                               3 w - 1%C2     470 uf       R33     64.9 ohms                               3 w - 1%C4     4.7 uf       R28     1K ohms 1/2 wC10    4700 pf (250 V)               D7      1 N 4004               ZD1     12 V               ZD3     18 V______________________________________ 
    
     With reference to FIG. 3 the circuit components of FIG. 1 mounted on a suitable circuit board are received in the bottom housing half 30 having upstanding wall 32 infilled with a suitable electrically insulative but thermally conductive potting material such as two part epoxy (2850FTFR with catalyst LN2636-101) available from Emerson and Cuming Inc. Use of the epoxy potting provides insensitivity to vibration and facilitates locking of the top housing half 34 to half 30. Top housing half 34 is provided with downwardly depending skirt portions 36, 38, 40 which are received inboard of wall 32 prior to the curing of the epoxy and are of a length such that the distal free end of the skirts are spaced from the circuit board by approximately 0.001 inch to provide suitable holding area for the epoxy to adhere to. To further enhance the effectiveness of the lock the skirts are preferably provided with a plurality of lands and grooves 42, 44 as shown in FIG. 4. 
     Terminals T2, T1, M2, M1 and S2, S1 project upwardly from the epoxy and are received through terminal apertures in housing half 34. As best seen in FIG. 5 terminal block members T2, T1 are smaller than the remaining terminals in order to ensure that line power will not be connected to the output or sensor terminals. This obviates potential miswiring by field personnel or the like which otherwise could result in damaging the control circuit. 
     Terminal X, shown in FIGS. 1, 3 and 5 is used to disable the time delay feature connecting point X with S1 so that other features of the circuit can be tested more expeditiously. 
     Use of the power supply described above enables the over-temperature protection system to be used with a wide range of line voltages, from 30 to 264 V rms  without any change in the system&#39;s components or in the way that the system is connected to line voltage. Thus the over-temperature protection portion of the system can readily be used with 120 or 240 VAC applications. Additional advantages are obtained since the transformer, along with the diode rectifier network of the prior art, is replaced by the IC 24 thereby resulting in a reduction in size and weight of the system. Cost reduction is also achieved by replacing a conventional triac and its accessories with a low cost relay. The protection system built in accordance with the invention is not only less expensive due to the elimination of the transformer and reduction of inventory parts it is more reliable and is easily manufactured. 
     The protection system is particularly suitable for use with refrigerant compressor motors to provide protection from overheating due to locked rotor, running overload, light loads, loss of charge and high discharge gas temperature conditions. The system can be provided with or without the low voltage cut-out and time delay features. 
     It should be understood that though preferred embodiments of the invention have been described by way of illustrating the invention, the invention includes all modifications and equivalents of the disclosed embodiments falling within the scope of the appended claims.