Patent Document

[0001]     This application is a continuation of U.S. patent application Ser. No. 10/087,125, filed Mar. 4, 2002 for “Digital Fault Interupter with Self-Testing Capabilities.” 
         [0002]     The present invention claims benefit under 35 U.S.C. § 119(e) of a provisional U.S. patent application of John R. Baldwin entitled “Fault Interrupter Using Microprocessor for Fault Sensing and Automatic Self-Testing”, Ser. No. 60/286,372, filed Apr. 26, 2001, and of a provisional U.S. patent application of John R. Baldwin entitled “Digital GFCI”, Ser. No. 60/312,344, filed Aug. 16, 2001, the entire contents of said provisional applications being expressly incorporated herein by reference. 
     
    
     CROSS-REFERENCE TO RELATED APPLICATION  
       [0003]     Related subject matter is disclosed in a co-pending U.S. patent application of John R. Baldwin et al., filed on Nov. 28, 2000, Ser. No. 09/722,423, entitled “Fault Interrupter Using Microprocessor for Fault Sensing and Automatic Self-Testing”, the entire contents of said application being expressly incorporated herein by reference.  
       FIELD OF THE INVENTION  
       [0004]     The present invention relates generally to a fault interrupting device, such as a ground fault circuit interrupter or an arc fault circuit interrupter.  
       BACKGROUND OF THE INVENTION  
       [0005]     Fault interrupting devices are designed to trip in response to the detection of a fault condition at an AC load. The fault condition can result when a person comes into contact with the line side of the AC load and an earth ground at the same time, a situation which can result in serious injury. A ground fault circuit interrupter (GFCI) detects this condition by using a sense transformer to detect an imbalance between the currents flowing in the line and neutral conductors of the AC supply, as will occur when some of the current on the line side is being diverted to ground. When such an imbalance is detected, a relay or circuit breaker within the GFCI device is immediately tripped to an open condition, thereby removing all power from the load. Many types of GFCI devices are capable of being tripped not only by contact between the line side of the AC load and ground, but also by a connection between the neutral side of the AC load and ground. The latter type of connection, which may result from a defective load or from improper wiring, is potentially dangerous because it can prevent a conventional GFCI device from tripping at the intended threshold level of differential current when a line-to-ground fault occurs.  
         [0006]     A ground fault is not the only class of potentially dangerous abnormal operating conditions. Another type of undesirable operating condition occurs when an electrical spark jumps between two conductors or from one conductor to ground. This spark represents an electrical discharge through the air and is objectionable because heat is produced as an unintentional by-product of this unintentional “arcing” path. Such arcing faults are a leading cause of electrical fires. Arcing faults can occur in the same places that ground faults can occur; in fact, a ground fault would be called an arcing fault if it resulted in an electrical discharge, or spark, across an air gap. A device known as an arc fault circuit interrupter (AFCI) can prevent many classes of arcing faults.  
         [0007]     Some GFCI devices employ a microprocessor in conjunction with a conventional GFCI chip to perform self-testing functions. These GFCI devices typically provide distinct functions for each I/O port of the microprocessor. However, maximum temperature rise requirements are in place requiring the maximum temperature rise requirement to be lower in GFCI and AFCI devices. In order to meet these requirements while maintaining a low cost device, a need exists for a microprocessor within the GFCI or AFCI device to be able to receive a plurality of different inputs at a single I/O port of the microprocessor. By requiring fewer I/O ports, a smaller microprocessor can be used and heat dissipation can be reduced.  
         [0008]     Additional UL requirements allow for a maximum time period within which the load must be disconnected from the power supply in the event of a ground fault or arc fault. Some conventional GFCI and AFCI devices disconnect the load by de-energizing a solenoid to open contacts that had previously coupled the load to the AC supply. However, this arrangement dissipates excessive heat and may not be capable of opening the contacts within the time prescribed. Accordingly, a need exists for a novel circuit which continuously energizes the solenoid to maintain the contacts in a closed position, without generating excessive heat in the device.  
         [0009]     Although GFCI and AFCI devices can provide useful protection against electrical hazards, they may inadvertently create potentially dangerous situations. For example, if a ground fault circuit interrupter is inadvertently powered through its load or feed-through terminals rather than through its line or input terminals, the GFCI will trip normally when confronted with a ground fault condition but the load plugged into the GFCI receptacle will not be disabled. The miswiring may not be detected because electrical power is usually provided to the GFCI face receptacles some time after installation. Accordingly, the GFCI will remain incorrectly wired unless the installer is able to immediately detect the miswiring condition. Therefore, a need exists for a device that removes power from a receptacle coupled to a GFCI or AFCI, as well as all downstream receptacles, in the event that a miswiring condition occurs.  
       SUMMARY OF THE INVENTION  
       [0010]     According to one aspect of the present invention, a fault interrupter comprises a first and second input terminals for connection to the line and neutral terminals, respectively, of a power source; first and second output terminals for connection to the line and neutral terminals, respectively, of a load; and first and second conductive paths extending, between the first and second input terminals and the first and second output terminals; first and second contact sets for completing and interrupting the first and second conductive paths, respectively; an actuator for operating the first and second contact sets; and a first and second electronic switching device coupled to the actuator, the first electronic switching device being adapted to energize the actuator for a selected period of time, the second electronic switching device being adapted to energize the actuator after the first electronic switching device ceases operation.  
         [0011]     In accordance with a second aspect of the present invention provides a fault interrupter apparatus comprises first and second input terminals for connection to the line and neutral terminals, respectively, of a power source; first and second output terminals for connection to the line and neutral terminals, respectively, of a load; first and second conductive paths extending, between the first and second input terminals and the first and second output terminals; first and second contact sets for completing and interrupting the first and second conductive paths, respectively; a fault sensing circuit adapted to produce a fault signal in response to the detection of a fault condition at the load; and a processing device coupled to an output of the fault sensing circuit for receiving the fault signal and for operating the first and second contact sets to open the respective first and second conductive paths.  
         [0012]     In accordance with a third aspect of the present invention, a fault interrupter apparatus comprises first and second input terminals for connection to the line and neutral terminals, respectively, of a power source; first and second output terminals for connection to the line and neutral terminals, respectively, of a load; first and second conductive paths extending, between the first and second input terminals and the first and second output terminals; first and second contact sets for completing and interrupting the first and second conductive paths, respectively; and a processing device for operating the first and second contact sets in response to a plurality of input signals, wherein a single input of said processing device is adapted to receive more than one of said input signals.  
         [0013]     In accordance with a fourth aspect of the present invention a fault interrupter apparatus comprises first and second input terminals for connection to the line and neutral terminals, respectively, of a power source; first and second output terminals for connection to the line and neutral terminals, respectively, of a load; first and second conductive paths extending, between the first and second input terminals and the first and second output terminals; first and second contact sets for completing and interrupting the first and second conductive paths, respectively; and a controller for operating the first and second contact sets in response to the detection of a fault condition at the load, the controller being operative to periodically open the first and second contact sets, to monitor a voltage at the load to verify that the first and second contact sets have opened, and to re-close the first and second contact sets after a predetermined period of time after verifying that the first and second contact sets have re-closed, the predetermined period of time being extended by the controller if the first and second contact sets have not re-closed within the predetermined period of time.  
         [0014]     The present invention is also directed to methods which can be used in connection with the fault interrupting apparatus described above. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]     These and other aspects, advantages and novel features of the invention will be more readily appreciated from the following detailed description when read in conjunction with the accompanying drawings, in which:  
         [0016]      FIG. 1  is a schematic diagram of a ground fault circuit interrupter in accordance with a first embodiment of the present invention, in which a conventional GFCI chip is employed in combination with a microprocessor to operate the GFCI with a single I/O port of the microprocessor providing multi-input capabilities;  
         [0017]      FIG. 2  is a schematic diagram of a ground fault circuit interrupter in accordance with a second embodiment of the present invention, similar to the first embodiment of  FIG. 1 , but additionally providing a manual test switch in parallel with an SCR employed by the microprocessor to provide a simulated ground fault, and further comprising a reset button in series with the single I/O port of the microprocessor providing multi-input capabilities;  
         [0018]      FIG. 3  is a schematic diagram of ground fault circuit interrupter in accordance with a third embodiment of the present invention, similar to the second embodiment of  FIG. 2 , which employs a dual drive circuit in order to operate a solenoid within the GFCI;  
         [0019]      FIG. 4  is a schematic diagram of ground fault circuit interrupter in accordance with a fourth embodiment of the present invention, which employs a microprocessor that incorporates the functions of a conventional GFCI chip, and which employs a single drive circuit in order to operate a solenoid within the GFCI; and  
         [0020]      FIG. 5  is a schematic diagram of ground fault circuit interrupter in accordance with a fifth embodiment of the present invention, which employs a GFCI chip and a microprocessor, similar to  FIGS. 1-3 , except, the fifth embodiment employs a pair of relays or a double-pole double-throw relay to operate the GFCI. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0021]      FIG. 1  illustrates a receptacle-type ground fault circuit interrupter (GFCI)  5  constructed in accordance with a first embodiment of the present invention. The GFCI  5  employs a GFCI chip  10  with an output  12  to a microprocessor  14 . Microprocessor  14  is preferably a Type PIC12C67X or PIC12F629 microprocessor manufactured by Microchip, located in Chandler, Ariz. A field effect transistor (FET)  16  is powered, via the microprocessor  14 , to energize solenoid  15  thus closing contacts  18  and  20  to establish a conductive path between line terminals  22  and  24  and faceplate receptacles  38  and  40  and load or feedthrough terminals  26  and  28 .  
         [0022]     The GFCI  5  employs four sets of contacts, namely contact sets  18  and  20  in order to remove power from the face receptacles  38  and  40 , as well as any potential downstream receptacles, via wiring from load or feed-through terminals  26  and  28 . The contacts  18  and  20  are opened and closed simultaneously by a solenoid  15  preferably having specifications as detailed in the attached Appendix. A suitable solenoid  15  is available from Scientific Generics, located in Cambridge, England having a footprint of about 0.640 square inch, an aspect ratio of about 0.995, and dimensions of about 0.300 inch in height, 0.804 inch in width, and 0.800 inch in length. An alternative solenoid  15  is available from Bicron Electronics located in Canaan, Conn. having a footprint of about 0.650 square inch, an aspect ratio of about 1.500, and dimensions of about 0.650 inch in height, 0.650 inch in width, and 1.00 inch in length.  
         [0023]     The detection of a ground fault condition at a load connected to one of the face receptacles  38 ,  40  or to the feedthrough terminals  26  and  28 , is implemented by a current sense transformer  42  and a grounded neutral detection transformer  44 , the GFCI chip  10  which has a direct input into the microprocessor  14  via line  12 , as well as other interconnecting components. The GFCI chip  10  is preferably a Type RV4145N integrated circuit manufactured by Fairchild Semiconductor, located in South Portland, Me. The GFCI chip  10  and the microprocessor  14  are powered from the AC input terminals  22  and  24  by means of a full-wave bridge rectifier  29  and filter capacitor  31 . A transient voltage suppressor  25  is connected across the input terminals  22  and  24  to provide protection from voltage surges due to lightning and other transient conditions. As the transients increase, the voltage suppressor  25  absorbs heat. To prevent the voltage suppressor  25  from overheating and damaging and degrading the enclosure parts, a thermal fuse  27  is preferably provided between the power source  65  and the diode bridge  29  and varistor  25 . If the temperature reaches unacceptable levels, the fuse breaks the connection between the power source  65  and the combination of the bridge  29  and a varistor  25 , creating an open circuit condition, leaving the GFCI  5  inoperable for safety purposes.  
         [0024]     Within the GFCI  5 , a first conductor  30 , as mentioned above, connects the AC line input terminal  22  to the load line terminal  26 , and a second conductor  32  connects the AC neutral terminal  24  to the load neutral terminal  28 , in a conventional manner. Additionally, when contacts  18  and  20  make connections, the AC line input terminal  22  and AC neutral terminal  24  are coupled to the face receptacles  38  and  40 . The conductors  30  and  32  pass through the magnetic cores  46  and  48  of the two transformers  42  and  44 . The transformer  42  serves as a differential sense transformer for detecting a connection between the line side of the AC load and an earth ground (not shown), while the transformer  44  serves as a grounded neutral transformer for detecting a connection between the neutral side of the AC load and an earth ground. In the absence of a ground fault, the current flowing through the conductors  30  and  32  will be equal and opposite, and no net flux is generated in the core  46  of the differential sense transformer  42 . In the event that a connection occurs between the line side of the AC load and ground, however, the current flowing through the conductors  30  and  32  no longer precisely cancel and a net flux is generated in the core  46  of the transformer  42 . This flux gives rise to a potential at the output of the secondary coil  50 , and this output is applied to the input of the GFCI chip  10  to produce a trip signal on the output line  12 . As mentioned above, this output is fed directly into the microprocessor  14 , which in turn controls four sets of contacts  18  and  20 , via solenoid  15 , to remove the AC power from the face receptacles  38  and  40  and the load or feedthrough terminals  26  and  28 .  
         [0025]     Since the GFCI chip  10  is a commercially available component, its operation is well known to those skilled in the art, and need not be described in detail. In utilizing this device, the resistor  54  serves as a feedback resistor for setting the gain of the controller and hence its sensitivity to normal faults. Capacitors  52  and  58  provide noise filtering at the inputs of the controller. Capacitor  56  AC couples low frequency signals out of the sense transformer  42 , to the GFCI chip&#39;s  10  internal operational amplifier (not shown).  
         [0026]     It will be appreciated by those skilled in the art that the GFCI  5  should be wired with the AC source  65  at the line side  22  and  24  as opposed to the load side  26  and  28 . The GFCI  5  is structured and arranged to require the electronics to be powered from the line side  22  and  24  and to provide no power to the electronics when the GFCI  5  is miswired and powered from the load side  26  and  28 . In other words, if the power source  65  is connected at the hot  26  and neutral  28  terminals of the load side, no power is provided to the GFCI chip  10 , the microprocessor  14  and the solenoid  15 . Since the solenoid  15  is not powered, the contacts  18  and  20  are open. As such, there is no path from the load or feedthrough terminals  26  and  28  to the face receptacles  38  and  40 , which is a result of the GFCI  5  comprising four sets of contacts, as opposed to two sets of contacts.  
         [0027]     The contacts  18  and  20  are in a closed state when the solenoid  15  is energized. This state will be referred to as the normal state. However, when the solenoid  15  is not energized, the contacts  18  and  20  are in an open state and will be referred to as such.  
         [0028]     In operation, a ground fault can occur via a manual or self-test, or an actual ground fault, for example when a person comes into contact with the line side of the AC load and an earth ground at the same time. In a manual test described in more detail below, a user presses a test button  66 , thus grounding a half-wave rectified zero-cross signal ordinarily produced by the diode bridge  29  and the zero-cross voltage divider  75 . This grounded signal is input into microprocessor  14  via I/O port  68 . Microprocessor  14  then produces a test signal on line  70  to gate SCR  72 . As is well known in the art, an SCR begins to conduct when gated and will continue to conduct as long as current flows between its anode and cathode, even after the gating signal is removed. Thus the SCR  72  creates an imbalance between the conductors  30  and  32  by allowing an imbalance of current to flow through conductors  30  and  32 , thus, generating a net flux which gives rise to a potential at the output of secondary coil  50 . This output is applied to the input of GFCI chip  10 , which in turn signals the microprocessor  14  via line  12 . The microprocessor  14  de-energizes the solenoid  15  from a normal or on state to an off state, and the contacts  18  and  20  are moved from the normally closed state to an open condition, thereby removing power from the face receptacles  38  and  40  and from the load or feedthrough terminals  26  and  28 . The microprocessor  14  opens the contacts  18  and  20  momentarily (preferably for a period of time not to exceed 20 msec., in order to avoid disrupting the load during a manual or self test.  
         [0029]     The contacts  18  and  20  open within 20 msec, as specified by various standards, for example by the Information Technology Technical Industry Council (ITIC) in Washington D.C. The microprocessor  14  directly tests the load voltage, via opto-isolater  33  to determine whether the contacts  18  and  20  have opened. If an inductive load is coupled to the GFCI  5 , the microprocessor  14  continues to see a voltage at opto-isolater  33  due to the fact that an inductive load tends to maintain a voltage at the face receptacles  38  and  40  of the GFCI  5  for a longer period of time than a non-inductive load, despite the contacts  18  and  20  having opened. Accordingly, the microprocessor  14  de-energizes the contacts  18  and  20  for a longer period of time (preferably about 66.8 msec.) to ensure that any residual voltage is low enough such that it is undetectable at the load. If the microprocessor  14  determines that a voltage is still present after the longer period of time mentioned above, it illuminates a red LED  73  as an external alarm indicator.  
         [0030]     Maintaining low current consumption is important due to UL lead temperature rise requirements at the load  26  and  28 . As such, I/O ports of the microprocessor  14  can provide multiple functions. For example, the manual test button  66  shares an I/O port  68  with a voltage zero cross detection circuit via voltage divider  75 . The voltage zero cross detection circuit allows the microprocessor to determine when the incoming rectified sinusoidal signal is approaching a zero crossing. This enables the microprocessor  14  to close or open the contacts  18  and  20  at the zero crossing of an incoming AC signal, thus minimizing arcing at any of the contacts  18  and  20 .  
         [0031]     The microprocessor  14  is able to share the I/O port  68  with the two functions by reading the state of pin  74  to determine whether a line voltage is present. If the microprocessor  14  senses a loss of line voltage on port  68 , yet detects no load voltage present on port  74 , then the user has depressed the manual test button  66 . This is due to the fact that port  68  typically receives an input from voltage divider  75  that is representative of a half-wave rectified AC signal. Accordingly, when the manual test button  66  is depressed, the half-wave signal becomes zero, and the microprocessor  14  determines that the test button  66  has been depressed. Under normal operation, the microprocessor  14  employs the input for zero cross detection function, via voltage divider  75 , and processes it accordingly. The sharing of input ports on the microprocessor  14  allows for the use of a smaller and less complex microprocessor, which lowers power consumption and emitted heat.  
         [0032]     The automatic self-test, mentioned briefly above, is performed on a periodic basis, for example daily, weekly or monthly. The microprocessor  14  maintains a software record of the current state of the contacts  18  and  20  (i.e., either open or closed) and conducts an automatic self-test only if normal operation is in progress with the contacts  20  closed. During a self-test, pin  70  is brought high by the microprocessor  14  to drive the SCR  72  gate for 20 msec. Pin  76  looks for a ≧2.5 volt, 3.8 ms pulse from the GFCI chip  10  every 16.7 ms. When pin  76  receives a pulse, pin  78  is asserted low by the microprocessor  14  for 20 ms to open the contacts  18  and  20  momentarily, for example 20 msec. The microprocessor  14  checks pin  74  for a low signal for 20 msec. indicating that the contacts opened for 20 msec and then re-closed.  
         [0033]     Conventional GFCI devices open the contacts when the test button is activated and closes the contacts only when a reset button is activated. However, the GFCI  5  does not employ a reset button, rather the contacts  18  and  20  open and then re-close automatically, after which the GFCI  5  returns to normal operation, the microprocessor  14  flashes the green LED  80 . If the automatic test fails (i.e., if the GFCI chip  10  did not produce the required output, or if the contacts  20  did not open and re-close), the software is programmed to open the contacts  18  and  20  and flash the red LED  73 . An audible warning can also be added. If the user, depresses the manual test button two times, thus indicating a reset, the contacts will close. However, if a ground fault exists, the microprocessor opens contacts  18  and  20  despite the user depressing the manual test button twice.  
         [0034]     Turning now to the details of the manual test feature of device  5 , briefly mentioned above, when the contacts  18  and  20  are closed, then the manual test is implemented by momentarily activating the manual test button  66 . When the manual test button  66  is activated, the microprocessor  14  senses momentary loss of the zero cross circuit  75  function. Since the contacts  18  and  20  are closed (as sensed by pin  74 ), the microprocessor  14  can check that a line voltage is still present by checking that the pin  74  input is high, and can initiate a ground fault current via pin  70  and SCR  72 . The microprocessor  14  is continuously looking for an output from the GFCI chip  10  on pin  76 . When a ground fault begins, the GFCI chip  10  puts out a pulse (≧2.5 volt for 3.8 ms) every 16.7 ms on output  12 . When pin  76  detects this pulse from the GFCI chip  10 , the microprocessor  14  asserts pin  78  low for 20 ms to momentarily open the contacts  18  and  20  via FET  16 . When pin  78  goes low, the microprocessor  14  checks for a continuous zero voltage on pin  74  indicating the contacts  18  and  20  have opened. Pin  74  monitors an output from opto-isolater  33  to determine if a voltage exists. If the contacts  18  and  20  have not opened, then pin  74  has a continuous half-wave rectified signal. If the contacts  18  and  20  have opened for 20 msec., then pin  74  was low, the green LED  80  flashes and the device  5  passes. However, if pin  74  did not remain continuously at zero for 20 msec., the device  5  fails. The software maintains the contacts  18  and  20  open and flashes the red LED  73 . At this point, the user can press the manual test button  37  a second time. The microprocessor  14  interprets the user pressing the manual test button  66  twice as a reset command and repeats the test by having the microprocessor  14  assert pin  78  low for 20 msec. to momentarily open the contacts  18  and  20  via FET  16 , and repeats the above steps. If the test passes, the microprocessor  14  closes the contacts  18  and  20 . However, if this second test (i.e., depressing the manual test button a second time) fails, the microprocessor  14  does not close contacts  18  and  20 .  
         [0035]     Alternatively, the software of the microprocessor  14  allows the first push of the manual test button  66  to open the contacts  18  and  20  for an extended period of time. The second push of the manual test button  66  would re-close contacts  18  and  20 .  
         [0036]     With continued reference to  FIG. 1 , the operation of the microprocessor  14  facilitates operation of GFCI device  5  when a line voltage brown-out or a line voltage drop-out occurs. A brown-out situation occurs when the microprocessor  14  has sufficient supply voltage to enable the microprocessor  14 , yet the GFCI device  5  has insufficient voltage to operate the solenoid  15  in order to maintain power to the face receptacles  38  and  40 . When the line voltage drops below the solenoid  15  hold-in voltage, the solenoid  15  de-energizes and the contacts  18  and  20  open. The drop-out of the line voltage is detected by monitoring the zero cross circuit  75  via pin  68  and the load voltage via pin  74 . Accordingly, when the zero-cross function drops below a threshold voltage, a brown-out situation occurs.  
         [0037]     The microprocessor  14  has an internal Power On Reset (POR) circuit which holds the microprocessor in reset until V CC  from the power source  65  rises above 2.1 volts. Selecting a lower than 2.1 volts BOD trigger level allows the maximum time after a line voltage drop or sag before the microprocessor  14  is reset.  
         [0038]     Accordingly, two main scenarios can occur. For example, if a line voltage drop-out lasts long enough for V CC  to drop below 2.1 volts, then the contacts  18  and  20  open and the microprocessor  14  enters reset mode, wherein the microprocessor ceases functioning, and then goes through the normal start up process. In addition, if a line voltage brown-out lasts long enough or drops the line voltage low enough for the solenoid  15  to de-energize but not for the microprocessor  14  to be reset, then the software maintains drive to FET  16  via pin  78  until the line voltage is sufficiently re-established to operate the solenoid  15  and re-close the contacts  18  and  20 . If the contacts  18  and  20  were not closed, the mode of operation of the microprocessor  14  prior to the brown-out is continued.  
         [0039]     If a ground fault exists prior to a line voltage drop-out, when the GFCI  5  re-starts the normal warm-up proceeds. Following a 10 second warm-up, for example, the microprocessor  14  asserts pin  78  high to energize the solenoid  15  and close the contacts  18  and  20 . When the contacts  18  and  20  close, if the ground fault still exists, the GFCI chip  10  sends a pulse to pin  76  and the microprocessor  14  de-energizes the solenoid  15  and opens the contacts  18  and  20 .  
         [0040]     The microprocessor  14  is configured with all 6 pins configured as input/output I/O&#39;s ports. With this programmed configuration, not only does pin  42  have external interrupt capability, but the remaining 5 pins have programmable interrupt pin change capability that allows one pin to take on the functions of another pin.  
         [0041]     In an additional embodiment of the present invention, the microprocessor  14  software permits either a manual test only (no automatic test), or to monitor the load current and then conduct the automatic test only when the load current is zero or very low.  
         [0042]      FIG. 2  illustrates a second embodiment of the GFCI  100  with an external reset button  106 . The reset button  106  allows the solenoid  15  to be re-energized, thereby returning the contacts  18  and  20  to a normal or closed state. The zero cross detection circuit  75  and the reset button  106  share a common I/O port  68  on microprocessor  14  as in the GFCI  5  of  FIG. 1 .  
         [0043]     An additional modification in the embodiment of  FIG. 2  is the location of the manual test button  108  which is connected in parallel with the SCR  72 . In operation, when the manual test button  108  is depressed, it creates a shunt across SCR  72  and generates a simulated ground fault current that is detected by the GFCI chip  10 . The manual test then proceeds as described above in connection with the manual test of  FIG. 1 .  
         [0044]     In the embodiment of  FIG. 2 , microprocessor  14  cannot distinguish between a manual test and an actual ground fault due to the location of the manual test button  108 . Accordingly, the microprocessor  14  cannot be reset automatically after a manual test, as was possible in the embodiment of  FIG. 1 . Nor can the manual test button be depressed twice to initiate a reset as in  FIG. 1  because the second press of the manual test button is indistinguishable from an actual ground fault condition. Therefore, a reset button  106  is provided. The components and operation of the GFCI  100  of  FIG. 2  are similar in all other respects to the GFCI  5  of  FIG. 1 .  
         [0045]      FIG. 3  illustrates a GFCI  110  with a dual drive circuit  105  to energize solenoid  15  to close the contacts  18  and  20  within 20 msec. as prescribed by typical standards for electrical equipment. The dual drive circuit  105  comprises transistors  112  and  114  along with resistor  116 . The remainder of the components of  FIG. 3  are the same and described in detail above in connection with  FIG. 2 .  
         [0046]     In operation, the GFCI  110  operates in all three modes, namely, self test, automatic test, and actual ground fault, in the same fashion as  FIG. 2 . However, GFCI  110  energizes the solenoid  15  via the dual drive circuit  105 . When microprocessor  14  drives the solenoid  15  via line  78 , transistor  112  turns on and draws in the solenoid  15  plunger to allow the contacts  18  and  20  to be closed in a normal state. No current flows through transistor  114  because transistor  112  has shunted current from transistor  114 . As capacitor  113  becomes fully charged, it shuts off current flow to transistor  112  and allows it to turn off Substantially simultaneously, transistor  114  is turned on, in the second mode of operation, and maintains solenoid  15  in a normal state with its current output diminished due to series resistor  116 . The purpose of this dual mode of operation is to allow the GFCI  110  to run cooler by driving solenoid  15  with an initially high current (resulting from the absence of a current limiting resistor in the collector circuit of transistor  112 ) to draw in the solenoid plunger to close the contacts  18  and  20 , then dissipating less current via transistor  114  which is current limited, via resistor  116 . Accordingly, this dual mode allows for higher power dissipation by transistor  112  to initially actuate solenoid  15 , but requires less power dissipation to maintain the solenoid  15  in the current state, via transistor  114 . The solenoid  15  available from Bicron Electronics, described above, is operable with the dual drive circuit  105  of  FIG. 3 . The decreased power provided by transistor  114  is sufficient to maintain operation of this solenoid.  
         [0047]      FIG. 4  illustrates a GFCI  120  that employs a microprocessor  122  both for detecting ground faults, and for conducting self-tests. The GFCI  120  does not employ a separate GFCI chip  10 , as do the embodiments of  FIGS. 1-3 ; rather, the functions of the GFCI chip are incorporated into the microprocessor  122 . The microprocessor  122  is preferably a Type CYC26233 or CY8C26443 microprocessor manufactured by Cypress Microsystems located in Bothell, Wash. The GFCI  120  also comprises a reset button  124  to manually reset contacts  18  and  20 . The GFCI  120  does not include a manual test button because the GFCI device  100  automatically tests itself periodically. Additionally, the GFCI  120  employs a single drive circuit  121  to energize solenoid  15 . The circuit  121  comprises a transistor  126  and a resistor  128 . Additionally, a green LED  80  is in the emitter circuit of transistor  126  such that it receives power directly from the diode bridge  29 , rather than from the microprocessor  122 . The green LED  80  functions as an external indicator for the self test, as described below. All the other components are the same as those described in connection with the GFCI  110  of  FIG. 3 .  
         [0048]     In operation, the microprocessor  122  detects an actual fault via the outputs of the sense transformer  42  and the grounded neutral transformer  44  (detecting the imbalance in the current flow between the conductors  30 ,  32 ,  34 , and  36  as described above in connection with  FIG. 1 ). Specifically, the microprocessor  122  receives an input from the sense transformer  42  on I/O ports  134  and  136 . The microprocessor  122  includes an internal operational amplifier that amplifies the signal received on I/O ports  134  and  136 . The microprocessor  122  feeds this amplified signal to a window detector to determine whether a ground fault exists, in order to open contacts  18  and  20 . A threshold voltage of the window detector is based upon the operating voltage. Specifically, the voltage regulator  138  for the microprocessor  122  operates at approximately 5 volts. Accordingly, the threshold voltages, in this case, are 1 volt for the lower threshold and 4 volts for the upper threshold, or 1.5 volts and 3.5 volts, respectively. If the microprocessor  122  determines that the amplified signal is less than the minimum threshold or exceeds the maximum threshold, the processor  122  initiates signaling to the single drive circuit  121  via port  130 . For example, the amplified signal would drop below the threshold if a ground fault occurs when the incoming AC line voltage is going in the negative direction of the incoming sinusoidal line voltage. Alternatively, if the ground fault occurs when the incoming line voltage is going in the positive direction of the incoming sinusoidal line voltage, the amplified signal would be greater than the maximum threshold. The transistor  126  is gated off, thus de-energizing solenoid  15  to open contacts  18  and  20  in order to remove power from the load. The microprocessor  122  monitors the voltage on I/O port  132 . If no voltage is present, the contacts  18  and  20  have opened. The user can activate the reset button  124  which allows the solenoid  15  to be energized via microprocessor  122 . However, if a voltage is present, and the microprocessor  14  has attempted to have the contacts  18  and  20  held open for a sufficient period of time, the GFCI  120  is malfunctioning. In such a case, the red  73  LED flashes and the microprocessor  122  de-energizes solenoid  15  via port  130 .  
         [0049]     In the case of a microprocessor self-test, which occurs periodically, the microprocessor  14  gates SCR  72  via port  131  thereby creating an imbalance in the flux between conductors  30 ,  32 ,  34 , and  36  (described above in connection with  FIG. 1 ). The microprocessor  122  receives an input from the sense transformer  42  on I/O ports  134  and  136 . The microprocessor  122  includes an internal operational amplifier that amplifies the signal received on I/O ports  134  and  136 . The microprocessor  122  feeds this amplified signal to an internal window detector, as described above in connection with the manual test. The microprocessor  122  outputs a signal on line  130  to de-energize solenoid  15  and thereby opening contacts  18  and  20 . The microprocessor monitors the voltage on I/O port  132  to determine if the power source has been removed from the load, as described above. If a voltage is present on I/O port  132 , the microprocessor waits 100 msec. and repeats the test.  
         [0050]     The microprocessor  122  performs the self-test up to four times, consecutively, and may still achieve a pass. However, if the microprocessor fails after a fourth test has been completed and has failed all four tests, the microprocessor automatically alerts the user of the condition by flashing red  80  LED and opening contacts  18  and  20 .  
         [0051]      FIG. 5  depicts a GFCI  140  employing a separate GFCI chip  10  as in  FIGS. 1-3 , but with relays  148  in place of the discrete solenoid  15  and contacts  18  and  20 . However, the GFCI  140  of  FIG. 5  employs a half-wave input  146  as opposed to a full wave bridge as in  FIGS. 1-4 . The half wave rectifier  146  provides a half-wave rectified sinusoidal signal as its output. The GFCI  140  can employ a half-wave power supply due to the fact that the relays  148  can operate with low coil voltage on the order of approximately 12 volts, as opposed to the solenoid  15  of  FIGS. 1-4  which operates at the line voltage of the incoming AC supply. Accordingly, the relays  48  does not require a fully rectified sinusoidal voltage, but rather a half wave rectified voltage is sufficient. The half wave rectifier  146  is less expensive due to the fewer number of diodes required.  
         [0052]     The GFCI  140  of  FIG. 5  employs two sets of relays  148 , as opposed to four sets of contacts as shown in the previous embodiments of the present invention in  FIGS. 1-4 . Accordingly, the GFCI  140  does not include any reverse wiring protection for the face contacts  38  and  40  as do the embodiments of  FIGS. 1-4 .  
         [0053]     The manual test of GFCI  140  is preferably provided by activating manual test button  66  which creates a shunt across the SCR  72  thereby initiating a simulated ground fault detected by the GFCI chip  10  and microprocessor  14  as detailed above in connection with  FIG. 2 . The microcontroller  14  operates relays  148  via Darlington transistors  142  and  144 . If the GFCI  140  does not pass the manual test the red LED  80  flashes and contacts  18  and  20  are opened. A self-test is initiated by the microprocessor  14  gating SCR  72  via line  70  and proceeding as explained above in connection with 2.  
         [0054]     Although only a few exemplary embodiments of the present invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims and equivalents thereof.  
       Appendix  
       [0055]    
       
         
               
               
             
           
               
                   
               
               
                   
               
             
             
               
                 Total time for Contacts to 
                 16.7 msec. 
               
               
                 open and re-close 
               
               
                 Holding Force in Fully Pulled- 
                  2.7 lbs. 
               
               
                 In Position (d = 0″) 
               
               
                 Initial Pull Force when First 
                 0.15 lbs. minimum 
               
               
                 Energized (d = .040″) 
               
               
                 Stroke 
                 0.040″ 
               
               
                 Ambient Temperature 
                 −35° C. to 66° C. 
               
               
                 Required PC Board Area 
                 Smaller than 1.00″ by 0.65″ 
               
               
                 Coil Hot Spot Temperature 
                 Less than 95° at 25° C. ambient 
               
               
                 Coil Operation 
                 Normal operation is continuously on; 
               
               
                   
                 powered by a full wave rectified 120 
               
               
                   
                 VAC signal (+10%-15%)

Technology Category: 5