Patent Grant
8717731
National energy codes first appeared in the 70's as a response to the global energy crisis. The historically high oil prices and the resulting shock to the economy prompted a focus on how energy is used and, more importantly, how it may be wasted. Little attention was paid to the efficiency of a building's design or cost of operation before that time. The American Society of Heating Refrigeration and Air-Conditioning Engineers (ASHRAE) was at the forefront of energy code development, publishing the first industry standard in 1975. This standard has continued to evolve with input from the building community and as new technology became available. With a purpose to reduce energy use while still maintaining occupant comfort, ASHRAE Standard 90.1 has become the standard for design and construction in the United States and has a strong influence on commercial building designs throughout the world. The 2010 revision to this standard includes a new requirement to reduce energy consumption by controlling plug load circuits.
In one embodiment, an apparatus includes a controlled circuit breaker and an uncontrolled circuit breaker. The controlled circuit breaker is configured to input and output current generated by a first voltage phase. The controlled circuit breaker also includes a control mechanism operably coupled to a first pair of separable contacts that opens the first pair of separable contacts to interrupt the current generated by the first voltage phase in response to a control signal. The uncontrolled circuit breaker is configured to input and output current generated by a second voltage phase that is different than the first voltage phase. The uncontrolled circuit breaker also includes a trip mechanism configured to selectively open a second pair of separable contacts to interrupt the current generated by the second voltage phase in response to an overload event. The controlled circuit breaker and the uncontrolled circuit breaker are mechanically connected to one another in fixed relative positions such that when the apparatus is installed in a circuit breaker panel, the controlled circuit breaker and the uncontrolled circuit breaker are installed in adjacent slots.
In one embodiment, the controlled circuit breaker and the uncontrolled circuit breaker are configured to share a neutral conductor. In one embodiment, the controlled circuit breaker further includes a trip mechanism configured to open the first pair of contacts or, alternatively, a separate set of contacts, to interrupt the current generated by the first voltage phase in response to an overload event. The control mechanism may be a solenoid or a motor that responds to the control signal to separate the first pair, or alternatively, the separate set of contacts.
In one embodiment, the controlled circuit breaker includes a first handle manually operable to open a pair of contacts to interrupt the current generated by the first voltage phase. The uncontrolled circuit breaker also includes a second handle manually operable to open the second pair of contacts to interrupt the current generated by the second voltage phase. The apparatus further comprises a handle tie that mechanically couples the first handle to the second handle such that operation of one of the first and second handles will open the pair of contacts and the second pair of contacts to interrupt the current generated by the first voltage phase and the current generated by the second voltage phase.
In one embodiment, the apparatus includes a common trip mechanism coupled between a pair of contacts in the controlled circuit breaker and the second pair of contacts in the uncontrolled circuit breaker. The common trip mechanism is configured to, in response to opening of one of the pair of contacts and the second pair of contacts, cause the other of the pair of contacts and the second pair of contacts to open.
In one embodiment, an apparatus includes a first circuit breaker and a second circuit breaker. The first circuit breaker includes a first input connector configured to be electrically connected to a first conductor and a control mechanism operably coupled to a first pair of contacts. The control mechanism is configured to selectively open and close the first pair of contacts in response to a control signal. In this manner, the first pair of contacts controls a flow of current through the first conductor. The control mechanism may be a solenoid or a motor that responds to the control signal to separate the first pair of contacts.
The second circuit breaker includes a second input connector configured to be electrically connected to a second conductor and a trip mechanism operably coupled to a second pair of contacts. The trip mechanism is configured to selectively open the second pair of contacts in response to an overload event on the second conductor. In this manner, the second pair of contacts controls a flow of current through the second conductor. The first circuit breaker is mechanically connected to the second circuit breaker such that the first input connector and the second input connector are electrically isolated from one another. The controlled circuit breaker and the uncontrolled circuit breaker may be configured to share a neutral conductor.
In one embodiment, the controlled circuit breaker includes a trip mechanism operably coupled to the first pair of contacts, or alternatively, a third pair of contacts. The trip mechanism is configured to open the first pair, or alternately, the third pair, of contacts to interrupt the current generated by the first voltage phase in response to an overload event.
In one embodiment, the controlled circuit breaker includes a first handle manually operable to open a pair of contacts to interrupt the current generated by the first voltage phase. The uncontrolled circuit breaker also includes a second handle manually operable to open the second pair of contacts to interrupt the current generated by the second voltage phase. The apparatus further comprises a handle tie that mechanically couples the first handle to the second handle such that operation of one of the first and second handles will open the pair of contacts and the second pair of contacts to interrupt the current generated by the first voltage phase and the current generated by the second voltage phase.
In one embodiment, the apparatus includes a common trip mechanism coupled between a pair of contacts in the controlled circuit breaker and the second pair of contacts in the uncontrolled circuit breaker. The common trip mechanism is configured to, in response to opening of one of the pair of contacts and the second pair of contacts, cause the other of the pair of contacts and the second pair of contacts to open.
In one embodiment, a system includes an uncontrolled circuit breaker, a controlled circuit breaker, a first outlet, and a second outlet. The uncontrolled circuit breaker is connected to a first conductor in a first circuit. The first conductor is connected to a first electrical phase. The controlled circuit breaker is connected to a second conductor in a second circuit. The second conductor is connected to a second electrical phase that is different from the first electrical phase. The first outlet receives power from the first conductor; and the second outlet receives power from the second conductor. The first outlet and second outlet may be disposed on a same duplex outlet or different duplex outlets. The first and second circuits may share a neutral conductor.
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate various systems, methods, and other embodiments of the disclosure. It will be appreciated that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one embodiment of the boundaries. One of ordinary skill in the art will appreciate that in some embodiments one element may be designed as multiple elements or that multiple elements may be designed as one element. In some embodiments, an element shown as an internal component of another element may be implemented as an external component and vice versa. Furthermore, elements may not be drawn to scale.
Energy codes set minimum requirements for energy-efficient design and construction for new and renovated buildings. Over the next few years switched receptacles will become law as energy codes are updated across the United States. Remote control circuit breaker systems provide a convenient method to meet this new requirement.
With every update of 90.1, ASHRAE sets a goal to improve energy savings over the previous version. With many improvements to lighting and HVAC efficiency already in place, miscellaneous electrical loads became an obvious target for additional energy savings. Non-essential plug loads are almost always left connected to receptacles when occupants are away. The “stand-by” power that these loads consume is a significant portion of energy consumption. The portion of energy consumption by non-essential plug loads will continue to rise as the efficiency of other systems improves. Controllable plug loads, such as task lights, printers, and computer monitors can be automatically “unplugged” by simply switching off the power supplied to the receptacle.
ASHRAE 90.1-2010 Section 8.4.2 stipulates automatic shut-off control of at least 50% of the receptacles installed in private offices, open offices and computer classrooms, including receptacles installed in modular partitions. Control options for shut-off include a time-of-day schedule, occupancy sensor, or by a signal from another system. This new requirement ensures that the controlled receptacle capability is provided in a building but allows flexibility in how it is used. At least one switched receptacle is to be provided near each uncontrolled receptacle. Occupants have the choice whether a load is plugged into a controlled receptacle. The occupant ultimately decides which loads are suitable for automatic shut-off without causing disruption to their business.
There are several ways that a building can be made to comply with Section 8.4.2. Switching of the controlled receptacle circuit can occur at either a remote controlled circuit breaker panel, a relay panel, or by an occupancy sensor located in the controlled area. The remote controlled circuit breaker panel is a versatile option. The remote controlled circuit breaker panel will already include an internal time clock for time-of-day control to meet the control requirement. Additionally, the remote controlled circuit breaker panel is capable of responding to external signals from occupancy sensors or other systems via a simple connection. The hybrid control circuit breaker described herein is configured to provide remote controlled and uncontrolled circuit breaker capabilities in a single unit that is suitable for being installed in the remote controlled circuit breaker panel.
Sharing a neutral conductor among several circuits is a common practice in commercial construction since it reduces the total number of wires, reduces voltage loss and heat, and reduces conduit fill. This practice is more likely with the new requirement to control receptacles since two circuits can supply a split duplex receptacle, two duplex receptacles in the same wall box, or even separated receptacles in the same area. It is a natural approach to wiring, especially when a centralized control system is used for switching a circuit. But particular attention needs to be paid to ensuring that controlled and uncontrolled receptacles follow electrical code requirements for multi-wire branch circuits when both do not originate from the same branch circuit.
A potentially non-compliant situation exists when receptacles supplied from different circuits on the same phase share a neutral conductor. The current through the neutral conductor is the total supplied by the two circuits, potentially exceeding the rating. Although the neutral conductor could be an appropriately sized larger gauge of wire, a second problem remains when the circuit is serviced if both branches are not disconnected. It is not possible to link the two branch breakers with a handle tie to create a simultaneous disconnect means since same phases are not adjacent in the circuit breaker panel. Keeping the two circuits separate by using individual neutral wires and locating the receptacles in different wall boxes would avoid these hazards. The hybrid control circuit breaker described herein is configured to be installed in adjacent slots in the circuit breaker panel. Input connections for the remote controlled circuit breaker and the uncontrolled circuit breaker are separate from one another. When installed in a panel, the remote control circuit then controls a branch circuit on a first phase and the uncontrolled circuit breaker supplies a branch circuit on a second phase.
The hybrid control circuit breaker 20 includes a controlled circuit breaker 50. For the purposes of this description, a controlled circuit breaker is a circuit breaker that is equipped to disconnect power in response to a control signal. Controlled circuit breakers may be called “remote controlled” circuit breakers in some contexts. The control feature of the controlled circuit breaker 50 is designated by the normally open contact symbol 55. The controlled circuit breaker 50 may also sometimes be distinguished by an override handle 59 (
The controlled circuit breaker 50 also includes a reset handle 52 that allows a user to manually operate contacts in the circuit breaker that are controlled by thermal (overload) conditions. The controlled circuit breaker 50 is connected to phase B and controls power in a controlled branch circuit including a duplex outlet 14 that supplies power from phase B. An example embodiment of a controlled circuit breaker is shown in
Both the controlled branch circuit and the uncontrolled branch circuit may share a neutral conductor. A handle tie shown schematically as dashed line 40 mechanically couples the handle 32 to the handle 52. This connection between the handles of two circuit breakers is required by some electrical codes when circuits controlled by the two breakers share a neutral.
In some embodiments, the hybrid control circuit breaker 20 is implemented using a multi-pole circuit breaker in which one of the poles is remote controlled. In the multi-pole circuit breaker, the overload trip mechanisms of the uncontrolled circuit breaker 30 and the controlled circuit breaker 50 are connected to one another with a common trip mechanism (not shown, internal to circuit breaker), such as a common trip bar, that causes adjacent poles to trip when a given pole trips due to an overload event. A multi-pole hybrid control circuit breaker with the common trip mechanism could be used in the shared neutral configuration described in
In the circuits shown in
The first set of contacts 150, 152 is controlled by a solenoid 188 that is actuated by a control switch 175 as will be described in more detail below. Thus, the switch 175 is responsive to a control signal (e.g., timer, occupancy sensor) to cause the solenoid 188 to open the contacts 150, 152. The second set of contacts 144, 146 are controlled by both a handle 152 and a trip mechanism 148. The operable mechanical connection between the handle 152 and the trip mechanism 148 and the second set of contacts 144, 146 is shown in dashed line. The operation of the handle 152 and trip mechanism 148, which can be effectuated in any of many known ways is not described in detail here.
The solenoid 188 operates a plunger 192 that is operably connected the first set of contacts 150, 152. When a control circuit for the solenoid 188 is unpowered (e.g., switch 175 is open), the plunger 192 is urged by an internal spring (not shown) into the extended or downward position shown in
When it is desired to disconnect power from the load 184, the remote switch 175 is closed, which completes a circuit from the voltage source 312 through conductor 298, a terminal 256, contacts 252, 254, a terminal 258 and conductor 302 to the pickup coil of solenoid 188, which circuit is returned through conductor 304, conductor 306 and the closed switch 175 to the source 312. A circuit is also completed from the voltage source 312 through conductor 298, and terminal 300 to energize the holding coil of the solenoid 188. Energization of the pickup coil and holding coil of the solenoid 188 causes upward retraction of the solenoid plunger 192 (as indicated by the arrow in
When plunger 192 is in its downward position, contacts 248 and 240 are closed, which completes a circuit through a voltage source 276 and a lamp 159a, which indicates that relay contacts 150 and 152 are closed, which in turn indicates that current is being supplied to load 184 (in the absence of a tripped condition of breaker contacts 144, 146), thus providing load management information and positive feedback indication. When the plunger 192 is in its upper position, the contacts 248 and 242 are closed, which completes a circuit through the voltage source 276 and a lamp 159b, indicating that relay contacts 150 and 152 are open, which in turn indicates that current is not being supplied to load 184. The lamps 159a and 159b may be incorporated into the indicator light 59 of
The hybrid control circuit breakers described herein require no special methods for wiring and no additional labor for installation. There are no additional devices to mount or equipment to install. The electrical contractor can simply wire receptacle circuits to a circuit breaker as they have always done. There are no additional connections through interposing relays or other devices since the circuit breaker has an internal relay. Having receptacle control imbedded inside the electrical gear reduces the number of products required on a job. No extra space is needed in the electric closet for an additional panel.
Contractors are already required to clearly mark each breaker to indicate the connection. If hybrid control circuit breakers are used, the separation of controlled and uncontrolled receptacles occurs in one location where they can be precisely labeled according to their function. More importantly, it would be evident which circuits share a common neutral and that they are connected to different phases. A handle tie across these same breakers allows easy identification, a common disconnect and simplifies lock-out tag-out safety procedures. In a remote controlled circuit breaker panel, all of the equipment is concentrated in one place for simple verification. Other approaches can require a more tedious and time consuming verification process.
One hybrid control circuit breaker manages an entire circuit of receptacles, potentially doing the job of many discrete devices. When designing a project, panel schedules can be marked by the engineer to indicate the controlled circuits, which correspond to the designated switched receptacles on the electrical drawing. Wiring per plan by the electrical contractor will ensure that the switched receptacle count meets the design intent. Instead of relying on occupancy or a schedule, receptacles can be controlled by the “armed away” status signal from the security system or a system can logically combine multiple methods, such as using a schedule during normal business hours and an occupancy sensor at night. An added benefit is that savings generated by receptacle control can be calculated and logged as part of the system.
While for purposes of simplicity of explanation, the illustrated methodologies in the figures are shown and described as a series of blocks, it is to be appreciated that the methodologies are not limited by the order of the blocks, as some blocks can occur in different orders and/or concurrently with other blocks from that shown and described. Moreover, less than all the illustrated blocks may be used to implement an example methodology. Blocks may be combined or separated into multiple components. Furthermore, additional and/or alternative methodologies can employ additional blocks that are not illustrated.
References to “one embodiment”, “an embodiment”, “one example”, “an example”, and so on, indicate that the embodiment(s) or example(s) so described may include a particular feature, structure, characteristic, property, element, or limitation, but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element or limitation. Furthermore, repeated use of the phrase “in one embodiment” does not necessarily refer to the same embodiment, though it may.
While example systems, methods, and so on have been illustrated by describing examples, and while the examples have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the systems, methods, and so on described herein. Therefore, the disclosure is not limited to the specific details, the representative apparatus, and illustrative examples shown and described. Thus, this application is intended to embrace alterations, modifications, and variations that fall within the scope of the appended claims.
To the extent that the term “includes” or “including” is employed in the detailed description or the claims, it is intended to be inclusive in a manner similar to the term “comprising” as that term is interpreted when employed as a transitional word in a claim.
To the extent that the term “or” is used in the detailed description or claims (e.g., A or B) it is intended to mean “A or B or both”. When the applicants intend to indicate “only A or B but not both” then the phrase “only A or B but not both” will be used. Thus, use of the term “or” herein is the inclusive, and not the exclusive use. See, Bryan A. Garner, A Dictionary of Modern Legal Usage 624 (2d. Ed. 1995).
To the extent that the phrase “one or more of, A, B, and C” is used herein, (e.g., a data store configured to store one or more of, A, B, and C) it is intended to convey the set of possibilities A, B, C, AB, AC, BC, and/or ABC (e.g., the data store may store only A, only B, only C, A&B, A&C, B&C, and/or A&B&C). It is not intended to require one of A, one of B, and one of C. When the applicants intend to indicate “at least one of A, at least one of B, and at least one of C”, then the phrasing “at least one of A, at least one of B, and at least one of C” will be used.
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| Number | Date | Country | |
|---|---|---|---|
| 20130293998 A1 | Nov 2013 | US |
