This invention pertains to the field of electrical connections in hazardous locations where explosive gas may be present.
Most electrical plugs and receptacles are rated for use in ordinary locations, where explosive gas is not present. A spark can occur if current is flowing from the receptacle to the plug when the plug is disconnected from the receptacle. In a similar fashion, a spark can occur when a plug is first inserted into a receptacle. The National Electrical Manufacturer's Association (NEMA) defines several standards for ordinary-location plugs and receptacles. These standards are followed by most manufacturers. NEMA plugs and receptacles for ordinary locations are readily available and inexpensive.
A spark that occurs upon connection or disconnection can cause an explosion if explosive gas is present. For that reason, NEMA plugs and receptacles rated for ordinary non-hazardous locations are not normally permitted in hazardous locations where explosive gas might be present.
There are known examples of Explosion-Proof electrical plugs and receptacles intended for use in hazardous areas. These connectors are designed to allow explosive gas to be present in arcing and sparking equipment. The connectors are built strong enough to contain the resulting explosion and prevent it from propagating outside the connector. However, these connectors are large, heavy, and expensive. U.S. Pat. No. 7,537,472 shows one example of an explosion-proof plug and receptacle typical of the prior art. U.S. Pat. No. 2,697,212 shows another example.
There are many known examples of electrical receptacles that keep power disconnected until a plug is inserted. U.S. Pat. No. 8,770,998 uses an optical sensor to detect when a plug is fully inserted, and a relay to energize the receptacle at that time. However, this receptacle is not safe for use in a hazardous location where explosive gas may be present. The relay contacts can create a spark upon opening and closing. Also, there is a race condition when the plug is removed. If the relay contacts have not completely opened before the plug prongs disconnect from the receptacle connections, a spark can occur. Either of these sparking conditions could cause an explosion if explosive gas is present. In addition, the plug is not locked into the receptacle, so unintended disconnection might occur and cause a spark.
U.S. Pat. No. 6,678,131 describes arc-safe electrical receptacles. This design uses a switch to detect the presence of the plug and a relay to connect power to the plug and receptacle. However, these receptacles are not safe for use in hazardous locations. The relay contacts and the switch can both create sparks that can ignite explosive gas. In addition, the plug is not locked into the receptacle, so unintended disconnection might occur and cause a spark.
U.S. Pat. No. 8,926,350 describes a protective lockable female electrical outlet. This design uses sliding contacts to energize the receptacle when a plug is inserted. It has the advantage of locking the plug into the receptacle to prevent unintended disconnection. However, the sliding contacts can create sparks that can ignite explosive gas.
U.S. Pat. No. 8,062,069 describes a spark-free improved connector. This design uses a reed switch controlled by a magnet attached to a plunger to disconnect power from the contacts before they are separated. This design would be safe for use in a location containing explosive gas. However, reed switches are able to carry only very small currents. This design is intended mainly for communication systems where the current through the connectors is low. This design would not be capable of carrying 15 to 30 Amperes as required for industrial power distribution in hazardous locations. Also, this design does not use standard NEMA plugs and receptacles.
U.S. Pat. No. 4,591,732 uses a light barrier to signal a relay when the plug is fully inserted into the receptacle. However, the relay contacts can create sparks that can ignite explosive gas. Also, there is a race condition when the plug is removed. If the relay contacts have not completely opened before the plug prongs disconnect from the receptacle connections, a spark can occur at the plug prongs. In addition, the plug is not locked into the receptacle, so unintended disconnection might occur.
U.S. Pat. No. 4,995,017 describes a safety electrical receptacle and claims to prevent explosions. It uses a triac to block power from reaching the receptacle terminals until a plug is fully inserted. However, this design would not be safe or acceptable in an atmosphere containing explosive gas. There are switches and contacts in direct connection to the high-voltage power line. Any of these switches or contacts could cause a spark and a potential explosion in the presence of explosive gas.
An electrical connector is disclosed comprising a receptacle having openings, a plug having blades that may be inserted into the openings in the receptacle, elements on the receptacle and on the plug having cooperating parts that create a first disengagement stage of the plug from the receptacle, in which removal of the blades from the openings comprises a second disengagement stage, a sensor arrangement sensitive to the first disengagement stage to produce a signal that energizes or de-energizes a relay; and the relay being responsive directly or indirectly to the signal to disable power to the electrical connector before the second disengagement stage, the relay having an isolation feature to prevent contact of explosive gas with a spark created by the relay.
These and other aspects of the device and method are set out in the claims.
Embodiments will now be described with reference to the figures, in which like reference characters denote like elements, by way of example, and in which:
At the outset, it should be appreciated that like drawing numbers on different drawing views identify identical, or functionally similar, structural elements of the invention. While the present invention is described with respect to what is presently considered to be the preferred aspects, it is to be understood that the invention as claimed is not limited to the disclosed aspects.
Furthermore, it is understood that this invention is not limited to the particular methodologies, materials and modifications described and as such may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the present invention, which is limited only by the appended claims.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs. Although any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the invention, the preferred methods, devices, and materials are now described.
An electrical connector is formed of a plug and socket or receptacle. Design features are disclosed to allow an electrical connector to be freely connected and disconnected in a hazardous location where explosive gas might be present. The disclosed electrical connector may use, along with the design features, standard NEMA electrical plugs and receptacles, including twist-lock designs such as NEMA L21-30 and NEMA L5-15, and straight-blade designs such as NEMA 5-15 types.
The electrical connector with the design features is particularly intended for Zone 2 and Class I Division 2 hazardous locations where explosive gas may be present less than 10 hours per year. These hazardous locations comprise over 90 percent of the hazardous locations in most modern petrochemical facilities.
CSA Standard C22.2 No. 60079-15 Rule 20.1(a) defines the requirements for non-sparking plugs and receptacles in Zone 2 hazardous locations. The electrical connector has two stage design features that enable the electrical connector to meet this CSA standard. The electrical connector disconnects power from the receptacle unless the plug is fully inserted and locked into position in the receptacle. A sensor arrangement detects when the plug is fully inserted and locked. The sensor arrangement turns on a relay which allows power to flow to the receptacle and the connected plug. The relay is encapsulated in epoxy 612 (
Before the plug can be disconnected, it must be unlocked in a first stage of disengagement. The sensor arrangement detects the unlocking action and releases the relay to disconnect power from the plug and receptacle. The plug can then be removed from the socket in a second disengagement stage. No spark occurs at the connection between the plug blades and the receptacle contacts, because electrical power is not present at that connection at the moment of disconnection. Explosive gas is kept away from the spark that occurs at the relay contacts by epoxy that encapsulates the relay or another isolation feature.
An electrical connector is shown in
When the plug 100 is first inserted into the receptacle 140 to the position shown if
To unplug the tool or appliance, the plug 100 is twisted counterclockwise with respect to the receptacle 140 to unlock it in a first disengagement stage This action causes the magnet 130 in the face of the plug 100 to become misaligned with the magnetic sensor 160 in the face of the receptacle 140. The sensor 160 de-energizes the relay coil 660, which causes the relay contacts 670 to open. This de-energizes the receptacle contacts 150 and the plug blades 110. A separate action or disengagement stage is required to pull the plug 100 out of the receptacle 140. This action does not cause an arc, because the power to the contacts was disconnected during the unlocking action. This embodiment is safe for use in Zone 2 and Class I Division 2 areas containing explosive gas, because no spark is created upon connection or disconnection. As an added benefit, the twist-locking plug cannot be inadvertently disconnected from the receptacle. It requires two distinct motions to unlock and then remove the plug from the receptacle.
This embodiment will often be used on three-phase power systems. In that case there are three energized (Hot) contacts in the receptacle, and three encapsulated relays are used to de-energize the Hot receptacle contacts, with one relay controlling each phase.
In an alternate version of this embodiment, the relays are installed in a Restricted Breathing enclosure 614, shown schematically in
Another embodiment is shown in
To modify the commercially available products for use in this embodiment, a permanent magnet 130 is embedded into the captive nut 180 on the plug 100, and two magnetic sensors 160-1 and 160-2 are embedded in the receptacle 140 near the male threads 200.
When the plug 100 is plugged into the receptacle 140 before rotation of the nut 180 to the position shown in
On
When the nut 180 has been tightened for at least one complete revolution, the engagement of the threads on the nut with the male threads on the receptacle makes it impossible to remove the plug from the receptacle. This condition occurs at time 240, and at this time it is safe to energize receptacle contacts 150 and plug blades 110, because they can no longer be disconnected to cause a spark. A microprocessor 680 is configured according to the timing diagrams of
At some time after time 240, clockwise rotation of nut 180 stops because the nut is tight. The microprocessor 680 stores the state of the relay coil output 340 in non-volatile memory and retains the relay coil output in the same High state until some later time when the nut is loosened. Power is allowed to flow to the tool or appliance as long as the nut is tight.
In summary, when the nut is being tightened, sensor 160-1 emits a High pulse before sensor 160-2. When the nut is being loosened, the pulse sequence is reversed.
When microprocessor 680 detects the sequence of pulses on signals 210 and 280 that indicates loosening of nut 180 has begun as shown in
In an alternate version of this embodiment, the relay is installed in a Restricted Breathing enclosure. The Restricted Breathing enclosure performs the same function as the encapsulation of the relay. Both methods keep explosive gas away from the arcing relay contacts and thus prevent explosion if explosive gas is in the atmosphere. Both Restricted Breathing and Encapsulation are acceptable protection methods for arcing and sparking components in Zone 2 hazardous locations as defined in CSA standard C22.2 No. 60079-15.
In all embodiments, the magnetic sensor 160 may be replaced by a reflective optical sensor and the magnet 130 can be replaced by a reflector. A sensor arrangement may also use a reflective optical sensor, in which, in place of magnet, a reflector is used. The sensor detects light only when reflected back from reflector to sensor.
When a magnetic sensor is used in the sensor arrangement, a piece of steel may be used to steer away unwanted magnetic flux. The steel goes counterclockwise from the sensor, as seen from the plug end. It sits about as far from the magnet when the plug is unlocked as the sensor does, but in the opposite direction rotationally. Flux from the magnet will tend to move in the direction of the steel, not the sensor. As the plug is locked, the magnet moves away from the steel and toward the sensor. This should increase the discrimination of the sensor between unlocked and locked. It may be better to use a more sensitive sensor if the sensor is not as affected by stray flux. Equipment for use in hazardous locations must not produce sparks that can ignite explosive gas.
A system is described which allows extension cords and power cords from electric tools to be plugged into and unplugged from a power source without causing electrical arcs or sparks. This system will be particularly useful in permanent and temporary power installations on single-phase and three-phase circuits rated at 120 Volts AC or higher and 15 Amperes or higher in Zone 2 and Class I Division 2 hazardous locations.
The electrical connector may be used for inexpensive electrical plugs, receptacles and extension cords that are safe for use in Zone 2 and Class I Division 2 hazardous locations. Objectives and advantages of the disclosed embodiments may include one or more of the following:
Thus, it is seen that the objects of the present invention are efficiently obtained, although modifications and changes to the invention should be readily apparent to those having ordinary skill in the art, which modifications are intended to be within the spirit and scope of the invention as claimed. It also is understood that the foregoing description is illustrative of the present invention and should not be considered as limiting. Therefore, other embodiments of the present invention are possible without departing from the spirit and scope of the present invention.
In the claims, the word “comprising” is used in its inclusive sense and does not exclude other elements being present. The indefinite articles “a” and “an” before a claim feature do not exclude more than one of the feature being present. Each one of the individual features described here may be used in one or more embodiments and is not, by virtue only of being described here, to be construed as essential to all embodiments as defined by the claims.
Number | Date | Country | Kind |
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2956033 | Jan 2017 | CA | national |