NZ229875A

NZ229875A - Circuit breaker modular option deck

Info

Publication number: NZ229875A
Application number: NZ229875A
Authority: NZ
Inventors: Andrew James Male
Original assignee: Westinghouse Electric Corp
Priority date: 1988-08-01
Filing date: 1989-07-07
Publication date: 1992-05-26
Also published as: IE892174L; MX164014B; BR8903774A; ZA895156B; KR0134633B1; KR900003940A; CN1022004C; CN1040111A; PH25695A; DE68925316T2; DE68925316D1

Description

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Pr.te: P.O. jQUKiOi, No: .A3..2?.U i NEW ZEALAND Pa ten ts Act 1953 N.Z. no./;V* cX ' » >;A • . • h • o \ COMPLETE SPECIFICATION MODULAR OPTION DECK ASSEMBLY We, WESTINGHOUSE ELECTRIC CORPORATION, Westinghouse Building, Gateway Center, Pittsburgh, Pennsylvania 15222, united States of America, a corporation organized and existing under the laws of the Commonwealth of Pennsylvania, united States of America do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:- - 1 - (Followed by 1A) 22 9 8 7 5 MODULAR OPTION DECK ASSEMBLY This invention relates to molded case circuit breakers and in particular to a modular option deck assembly for mounting optional devices, such as an undervoltage trip device and a shunt trip device to a 5 circuit breaker. Molded case circuit breakers are known as disclosed in the specification of U.S. Patent Nos. 4,489,295; 4,638,277; 4,656,444; and 4,679,018. Such circuit breakers are used to protect electrical circuitry 10 from damage due to an overcurrent condition, such as an overload and relatively high level short circuit. An overload condition is about 200-300% of the nominal current rating of the circuit breaker. A high level short circuit condition can be 1000% or more of the nominal 15 current rating of the circuit breaker. Molded case circuit breakers include at least one pair of separable contacts which may be operated either manually by way of a handle disposed on the outside of the case or automatically in response to an overcurrent 20 condition. In the automatic mode of operation the contacts may be opened by an operating mechanism or by a magnetic repulsion member. The magnetic repulsion member causes the contacts to separate under relatively high level short circuit conditions. More particularly, the 25 magnetic repulsion member is connected between a pivotally mounted contact arm and a stationary conductor. The magnetic repulsion member is a generally V-shaped member defining two legs. During high level short circuit 229875 conditions, magnetic repulsion forces are generated between the legs of the magnetic repulsion member as a result of the current flowing therethrough which, in turn, causes the pivotally mounted contact arm to open. 5 In a multipole circuit breaker, such as a three- pole circuit breaker, three separate contact assemblies having magnetic repulsion members are provided; one for each pole. The contact arm assemblies are operated independently by the magnetic repulsion members. For 10 example, for a high level short circuit on the A phase, only the A phase contacts would be blown open by its respective magnetic repulsion member. The magnetic repulsion members for the B and C phases would be unaffected by the operation of the A phase contact 15 assembly. The circuit breaker operating mechanism is used to trip the other two poles in such a situation. This is done to prevent a condition known as single phasing, which can occur for circuit breakers connected to rotational loads, such as motors. In such a situation, unless all 20 phases are tripped, the motor may act as a generator and feed the fault. In the other automatic mode of operation, the contact assemblies for all three poles are tripped together by a current sensing circuit and a mechanical 25 operating mechanism. More particularly, current transformers are provided within the circuit breaker housing to sense overcurrent conditions. When an overcurrent condition is sensed, the current transformers provide a signal to electronic circuitry which actuates the 30 operating mechanism to cause the contacts to be separated. Various devices are available to trip the circuit breaker for conditions other than overcurrent conditions. One such device is an undervoltage trip device. This device trips the circuit breaker when the 35 line conductors experience an undervoltage condition. This is done to protect loads, such as motors, from overheating during undervoltage conditions. Another type of device used to trip a circuit breaker for a condition, other than an overcurrent condition, is a shunt trip device. This device is comprised of a solenoid with a reciprocally mounted plunger. The shunt trip devices are generally used for circuit breakers being used as switches. In this situation, the circuit breaker is controlled from a remote location. Neither the undervoltage device nor the shunt trip device are required on all circuit breakers. Accordingly, they are options which are purchased as required. These options, when ordered, require custom building of the circuit breakers. Accordingly, such options can significantly increase the labor time and cost to fabricate such custom circuit breakers. According to the present invention, there is provided a circuit breaker comprising a housing having a base portion and a cover portion, one or more pairs of separable contacts disposed in said base portion, an operating mechanism including a trip bar for actuating said separable contacts, a modular option deck disposed adjacent said trip bar having an aperture for allowing communication with said trip bar, sets of slots integrally formed in said deck, a bracket having depending arms slidingly received in a selected set of said set of slots, and an option with an extending actuation lever mounted on the bracket, said extending actuation lever being in communication with the trip bar through said aperture. The invention will now be described, by way of example, with reference to the attached drawings wherein; 4 ?29y7 Figure 1 is a plan view of a molded case circuit breaker; Figure 2 is a cross-sectional view taken along line 2-2 of Figure 1; 5 Figure 3 is a cros3-sectianal view taken along line 3-3 of Figure 1 illustrating an outside pole; Figure 4 is a cross-sectional view taken along line 4-4 of Figure 2; Figure 5 is a perspective view of a portion of the 10 shock absorber assembly used for outside poles; Figure 6 is a cross-sectional view taken along line 6-6 of Figure 3; Figure 7 iss a cross-sectional view taken along line 7-7 of Figure 4; 15 Figure a is a plan sectional view taken along line 8-8 of Figure 7; Figure 9 is an enlarged cross-sectional view taken along line 9-9 of Figure 8; Figure 10 is an exploded perspective of the cam roller 20 pin assembly; Figure 11 is an exploded perspective of the laminated copper assembly; Figure 12 is an exploded perspective of the crossbar assembly; 25 Figure .13 is a bottom plan view taken along line 13-13 of Figure 2; % * (,y\ / ^ oi! ?29H7b 4(a) Figure 14 is a cross-sectional view taken along line 14-14 of Figure 2; Figure 15 is a plan sectional view taken along line 15-15 of Figure 14; . —— — *C>'\ C 5 229875 Figure 16 is a plan sectional view taken along line 16-16 of Figure 14; Figure 17 is a cross-sectional view taken along line 17-17 of Figure 1; and 5 Figure 18 is an exploded perspective view of the modular option deck assembly. Referring to the drawings a molded case circuit breaker 20, comprises an electrically insulated housing 21 having a molded base 2 2 and a molded co-extensive cover 10 24, assembled at a parting line 26. The internal cavity of the base 22 is formed as a frame 28 for carrying the various components of the circuit breaker. As illustrated and described herein, a Westinghouse Series C, R-frame molded case circuit breaker will be described. However, 15 the principles of the present invention are applicable to various types of molded case circuit breakers. At least one pair of separable contacts 30 are provided within the housing 21. More specifically, a main pair of contacts 3 0 are provided which include a fixed 20 main contact 32 and a movable main contact 34. The fixed main contact 32 is electrically connected to a line side conductor 36, bolted to the frame 28 with a plurality of fasteners 38. A T-shaped stab 40 is fastened to the line side conductor 36 with a plurality of fasteners 42. A 25 depending leg 44 of the stab 40 extends outwardly from the rear of the circuit breaker housing 21. This depending leg 44 is adapted to plug into a line side conductor disposed on a panelboard (not shown). Similarly, the movable main contact 34 is 30 electrically connected to a load side conductor 46 fastened to the frame 28 with a plurality of fasteners 48. Another T-shaped stab 50 is connected to the load side conductor 46 with a plurality of fasteners 52. A depending leg 53 of the stab 50, which extends outwardly 35 from the rear of the circuit breaker housing 21, is adapted to plug into a load side conductor within a panelboard. A donut-type current transformer (CT) 54 is 9 9 Q R 7 L. £ V.' disposed about the load side conductor 46. This current transformer 54 is used to detect current flowing through the circuit breaker 20 to provide a signal to an electronic trip unit (not shown) to trip the circuit breaker 5 20 under certain conditions, such as an overload condition. The electronic trip unit is not part of the present invention. An operating mechanism 58 is provided for opening and closing the main contacts 30. The operating 10 mechanism includes a toggle assembly 60 which includes a pair of upper toggle links 62 and a pair of lower toggle links 64. Each upper toggle line 62 is pivotally connected at one end to a lower toggle link 64 about a pivot point 66. Each of the lower toggle links 64 are 15 pivotally connected to a contact arm carrier 68 at a pivot point 70. The contact arm carrier 68 forms a portion of a crossbar assembly 72. The upper toggle links 62 are each pivotally connected to depending arms 73 of a cradle 74 at a pivot point 76. A biasing spring 78 is connected 20 between the pivot point 66 and an operating handle 80. The biasing spring 78 biases the toggle assembly 60 to cause it to collapse whenever the cradle 74 is unlatched from a latch assembly 82 causing the movable main contacts 34 to rotate about a pivot point 83 to cause the main 25 contacts 3 0 to separate. The latch assembly 82 latches the cradle 74 and toggle assembly 60. The latch assembly 82 includes a pair of latch links 84 and 86, pivotally connected end to end at a pivot point 88. The free end of the lower latch 30 link 84 is pivotally connected to the frame 28 about a pivot point 90. The free end of the upper latch link 86 is pivotally connected to a latch lever 92 about a pivot point 94. The other end of the latch lever 92 is pivotally connected to the frame 2 8 about a pivot point 35 96. Operation of the latch assembly 82 is controlled by a trip bar 98 having a depending lever 100 extending outwardly. The depending lever 100 engages a cam surface m 22 9 B 7 102, formed on the pivotally connected end of the upper latch link 8 6 when the latch assembly 82 is in a latched position. In response to an overcurrent condition, the trip bar 98 is rotated clockwise to move the depending 5 lever 100 away from the latch surface 102. Once the latch lever 92 has cleared the cam surface 102, a biasing spring 104, connected between the lower latch link 84 and the frame 28, causes the lower latch link 84 to toggle to the left causing the latch lever 92 to rotate clockwise 10 thereby releasing the cradle 74. Once the cradle 74 is released from the latch assembly 82, the cradle 74 rotates counterclockwise under the influence of the biasing spring 78. This causes the toggle assembly 60 to collapse which, in turn, causes the main contacts 3 0 to separate. The 15 circuit is reset by rotating the handle 80 to the CLOSE position. The handle 80 is integrally formed with an inverted U-shaped operating lever 106 which pivots about a pivot point 108. The trip bar 98 is controlled by an electronic 20 trip unit which actuates a solenoid (not shown) having a reciprocally mounted plunger which engages the lever 100 which, in turn, causes the trip bar 98 to rotate in a clockwise direction to unlatch the latch assembly 82. The electronic trip unit actuates the solenoid in response to 25 an overcurrent condition sensed by the current transformer 54. A laminated contact assembly 109 is formed from a plurality of individual movable main contact assemblies 110. The individual contact assemblies 110 are fastened 30 together to form the laminated contact assembly 109. The individual contact assemblies 110 include an elongated electrical conductor portion 111 and a contact arm portion 114. Some of the contact arm portions 114 carry the movable main contacts 34, while some are used to carry 35 arcing contacts 116. The contact arm portions 114 are coupled to stationary conductor portions 111 by way of repulsion members or flexible shunts 118. Several different types of individual contact 1* f b 10 15 20 25 30 22 9 8 7! 8 assemblies 110 are used to form the contact assembly 109. In a first type 119, an L-shaped conductor portion 111 is provided having an arcuate slot or keyhole 122 disposed on an edge on a short leg 124 of the L-shaped conductor 111. The keyhole 122 is used to receive an end of the magnetic repulsion member 118. The assembly 110 also includes a contact arm 114 having an irregular shape for carrying either a main movable contact 34 or an arcing contact 116 at one end. Another arcuate slot or keyhole 122, formed in the contact arm portion 114, disposed at an end opposite the main movable contact 34 or the arcing contact 116, is used to receive the other end of the magnetic repulsion member 118. The ends of the magnetic repulsion members 118 are crimped prior to being inserted into the keyholes 122. A top edge 128 of the contact arm portion 114 is formed with a rectangular recess 129 for receiving a biasing spring 13 0. The other end of the spring 130 seats against a pivotally mounted bracket 132. The top edge 128 of the contact arm portion 114 also includes an integrally formed stop 134. The stop 134 is used to stop movement of the contact arm 114 with respect to the pivotally mounted bracket 132. The spring 13 0 exerts a downward pressure or force on the contact arm portion 114 forcing it against the fixed main contact 32. This force may be about 4 to 5 pounds. The contact pressure from the spring 13 0 in conjunction with the magnetic repulsion forces produced as a result of current flowing in the magnetic repulsion member or shunt 118 controls the withstand rating of the circuit breaker. The withstand rating of a circuit breaker is the current at which the main contacts 30 begin to separate. Since the repulsion force generated by the magnetic repulsion member 118 is a function of the current flow through the magnetic repulsion member 118, the biasing springs 13 0 are used to oppose that force to control the withstand rating of the circuit breaker in certain conditions. Each contact arm portion 114 is provided with an ? L y d / J 9 aperture 136 for receiving a pin 139 for fastening the contact arm portions 114 together which defines a pivot point for the contact assembly 109. The stationary conductor portion 111 of each of the individual contact assemblies 110 5 is provided with three spaced-apart apertures 137 for receiving a plurality of rivets or fasteners 138 for fastening the stationary conductor portions 111 together. A preferred aspect of this embodiment of the invention relates to the method for connecting the contact assembly 109 10 to the base 22 of the circuit breaker housing 21. In conventional circuit breakers, the contact assemblies 109 are attached to the base of the circuit breaker by drilling and tapping holes in a base portion of the contact assembly. Fasteners are then screwed into the tapped holes to secure 15 the contact arm assembly to the circuit breaker base. However, in such an arrangement, the tapped holes may become loose over time due to the dynamic forces within the circuit breaker. This problem is solved by providing T-shaped slots in the bottom portion of the contact arm assembly 56 for 20 receiving square-headed bolts which are captured within the assembly 109. Accordingly, a second type of individual contact assembly 140 is provided having a T-shaped slot 142 formed on a bottom edge 144 of the stationary conductor portion 111. 25 This T-ahaped slot 142 is used to receive a square-headed bolt 147. The contact arm portion 114 of the assembly 140, as fc/v >-- %/ ^ C • '. Z ^ idPD f 10 9(a) ? 2 9 8 7 well as the magnetic repulsion member 110, are similar to those used in the contact assembly 110. Since the contact assemblies 140 with the T-shaped slots are sandwiched between adjacent contact arm assemblies which do not have such a T-ehaped slot 142 formed on the bottom edge, the square-headed bolt 112, after assembly, will be captured in the T-shaped slot 142. In another type of individual contact assembly 146, the stationary conductor portion 111 is similar to that provided with the contact assembly 119. The " t N / V *■> >\ 2 2 APR 1992 7! 10 229875 essential difference between the individual contact assemblies 110 and 146 is that the contact arm portions 114 in the assembly 146 carry arcing contacts 116 instead of main contacts 30 defining an arcing contact arm 148. 5 These arcing contacts 116 extinguish the arc caused when the main contacts 3 0 are separated. An arc suppression chute 152 is provided within the circuit breaker housing 21 to facilitate extinguishment of the arc. Each of the arcing contact arms 148 are formed with a rectangular 10 recess 129 for receiving a bracket 156 having parallel depending arms 158. The bracket 156 is received in the rectangular recesses 129. The bracket 156 also contains an upwardly-disposed protuberance 160 used to receive a spring 162 disposed between the bracket 160 and the 15 underside 163 of the pivotally mounted bracket 132. The arcing contact arms 148, similar to the main contact arm portions 114, are rotatable about the pivot point 137. The various types of individual contact assemblies 119, 140 and 146 are stacked together such that 20 the apertures 137 in the L-shaped conductor portions 111 are aligned. Rivets or fasteners 13 8 are then inserted into the apertures 13 6 to secure all of the L-shaped conductor portions 111 together. A pin or rivet defining a pivot point 139 is inserted through the apertures 13 6 in 25 the contact arm portions 114 and arcing contact arms 148 to connect all of the contact arm portions 114 together and to the pivotal bracket 132. Barriers 166 are placed between the stationary conductor portions 111 of the individual contact arm assembly and the shunts 118. 30 Barriers 166 are also provided between the individual contact arm portions 114 and 148. The completed assembly forms the contact assembly 109. The shunt or magnetic repulsion member 118 is a laminated member, form wound from a continuous, thin strip 35 of an electrical conductive material, such as copper, forming a laminated magnetic repulsion member. The form wound shunt member 118 is formed into a V-shaped member defining a pair of legs 168 and 17 0. Current flowing 0* 11 22 9 8 7 5 through the legs 168 and 17 0 causes magnetic forces to be generated which repels the legs 168 and 170 apart. Above a certain level of overcurrent (e.g., above the withstand rating), the magnetic repulsion forces developed will be 5 sufficient to blow open the main contacts 30 rather quickly. The biasing springs 13 0 oppose the magnetic repulsion forces generated by the magnetic repulsion member 118 to allow the current transformer 54 and the electronic trip unit to sense the overcurrent condition 10 and trip or separate the contacts by way of the operating mechanism 58 for overcurrent conditions less than the withstand rating of the circuit breaker. In order to improve the flexibility of the magnetic repulsion member, an apex portion 172 of the 15 member 118 is coined or deformed into a bulb-like shape is shown best in Figure 7. The extending legs 168 and 170 of the member 118 are crimped and inserted into the keyholes 122 in the stationary conductor portion 111 and the contact arm portions 114 of the individual main and arcing 20 contact arm assemblies. Once the ends of the shunt legs are inserted into the keyholes 122, the assembly is staked on both sides. The staking process provides a groove 174 in the assemblies adjacent the keyholes 122 to prevent wicking of solder used to secure the shunt legs 168 and 25 170 to the stationary conductor portions 110 and the contact arm portions 114 or 148. The cam roll pin assembly 17 6 is a dual-purpose assembly used to maintain the force between movable 34 and stationary contacts 32 during certain conditions, and 30 maintain contact separation between these contacts when a blow open occurs until the circuit breaker trips by way of the mechanical operating mechanism 58. During normal operation, when the overcurrent is less than the withstand rating of the circuit breaker 20, a cam roller pin 35 assembly 17 6 bears against a cam surface 180, integrally formed in the pivotally mounted bracket 132, which forms a portion of the contact arm assembly 109. This couples the crossbar assembly 72 to the contact arm assembly 109. 12 22 9 9 7 5 Since the toggle assembly 60 is coupled to the crossbar assembly 72, this will allow the operation of the main contacts 30 to be controlled by the mechanical operating mechanism 58. As heretofore stated, the biasing springs 5 130 in the contact assembly 109 will cause a downward pressure or force on the movable contact 34 against the fixed main contact 32. For overcurrent conditions less than the withstand rating of the circuit breaker 20, the contact arms 114 and 148 will pivot about an axis 137. 10 During such an overcurrent condition, the magnetic repulsion forces generated by the extending legs 168 and 170 of the magnetic repulsion member 118 will cause the contact arms 114 and 148 to rotate about the axis 139 in a counterclockwise direction forcing the main contacts 30 15 together to allow the operating mechanism 58 to trip the circuit breaker. In this situation, due to the pivotal movement of the contact arms 114 and 148 about the axis 137, the magnetic repulsion members 118 act to close or "blow on" the main contacts 30. 20 For overcurrent conditions below the withstand rating of the circuit breaker, the cam roller pin assembly 176 will ride in the cam surface 180 to mechanically couple the contact assembly 109 to the crossbar assembly 72. In this situation, the current transformer 54 will 25 sense an overcurrent condition and provide a signal to an electronic trip unit which will in turn cause the operating mechanism 58 to trip the circuit breaker and open the main contacts 30. However, for a relatively higher overcurrent condition, greater than the withstand 30 rating, the pivot point for the contact arm assemblies 109 will change to allow the contact assemblies 109 to blow open. More specifically, the magnetic repulsion forces generated by the magnetic repulsion member 118 will cause the cam roller pin assembly 176 to move away from the cam 35 surface 180 to a second cam surface 182 to allow the movable contact assembly 109 to pivot about another axis 183. In this situation, the magnetic repulsion forces generated by the magnetic repulsion member blow open the 13 22 9 87 5 main contacts 30. After blow open, once the cam roller pin assembly 176 reaches the cam surface 182, it will keep the main contacts 3 0 separated. Otherwise, after the overcurrent condition ceased, there would not be any 5 magnetic repulsion forces to keep the main contacts 3 0 separated. There are two points of contact at each end of the cam roller pin assembly 176 on the outside poles. One point of contact 184 is disposed intermediate the end. It 10 is the point where the cam roller pin assembly 176 rides along the cam surfaces 180 and 182 of the pivotally mounted bracket 132. The other point of contact 186 is at the ends of the cam roller pin assembly 176 where it is received within a pair of slots 188 in an electrically-15 insulated sleeve which forms a portion of the crossbar assembly 72. When a blow open condition occurs, the contact points 184 and 186 may rotate in opposite directions. In such a situation, relatively large torsional and frictional forces are created on the cam 20 roller pin assembly 176 which may cause the blow open speed to be reduced or possibly cause the breaker not to trip after blow open has occurred. In accordance with an important aspect of the present invention, a cam roller pin assembly 17 6 is provided which has independently 25 rotatable portions for each contact point 184 and 18 6 at each end to reduce the frictional and torsional forces which may be generated during a blow open condition. The cam roller pin assembly 176 includes a cylindrical portion 192 having extending axles 194 30 disposed at each end. A small roller 196 and a large roller 198 are disposed on each axle 194. After the rollers 196 and 198 are placed on the axle 194, a retaining ring 197 is used to secure the rollers 196 and 198 to the axle 194. The small roller 196 is used to 35 engage the cam surfaces 180 and 182 on the pivotally mounted bracket 132 while the larger roller 198 is received within the slot 188 in the electrically insulated sleeve 190. Since individual rollers are used for each of 14 2 2 9 8 7 5 the contact points, supported on a common axle, both rollers are independently rotatable. Thus, in situations where the contact points are forced to rotate in opposite directions, such as during a blow open condition, the 5 frictional forces will be greatly reduced, thus resulting in a smoother action of the circuit breaker 20. The cam roller pin assembly 176 is coupled to the pin 230 about which the pivotally mounted bracket 132 rotates, by way of a plurality of springs 200. Radial 10 grooves 204 formed in the cylindrical portion 192 of the cam pin roller assembly 176 receive hook shaped ends of the springs 200. Similar type grooves may be formed (not shown) on the pin 139 to receive the other end of the springs 200 to prevent axial movement of the springs 200 15 to couple the cam roller pin assembly 176 to the pin 23 0. The crossbar assembly 72 is coupled to the contact assemblies 109 for each of the poles by way of cam roll pin assemblies 176. More specifically, the crossbar assembly 72 includes an elongated shaft 206 which may be 2 0 formed with a rectangular cross section. The elongated shaft 2 06 is used to support a pair of contact arm carriers 68 coupled to the lower toggle links 64 of the toggle assembly 60. Two contact arm carriers 68 are provided adjacent the center pole in a multipole circuit 25 breaker 20. Each contact arm carrier 68 is generally L-shaped having an aperture 210 in a short leg 212. The aperture 210 is rectangular in shape and slightly larger than the cross sectional area of the shaft 2 06 such that the contact arm carriers 68 can be slidingly received on 30 the shaft 2 06 and rotate therewith. The contact arm carrier 68 is a laminated assembly formed from a pair of L-shaped brackets 214, spaced apart to receive the lower toggle link 64 from the toggle assembly 60. The apertures in the lower toggle 35 links 64 (defining the pivot point 70) are aligned with apertures 215 in the L-shaped members 214. Metal pins 216 are inserted through the apertures to form a pivotable connection between the contact arm carriers 68 and the 15 2 2 9 8 7 5 lower toggle links 64. Insulated sleeves 218 having a generally rectangular cross sectional bore are slidingly received on the ends of the crossbar shaft 206. These insulated sleeves 218 are disposed adjacent the outside 5 poles. Oppositely disposed plates portions 220 and 222 are integrally formed with the insulated sleeve 218 from an electrically insulating material. The plate portions 220 and 222 are disposed on opposite ends of the insulated sleeve 218 and contain a pair of inwardly facing rec-10 tangular slots 188. The pair of inwardly facing slots 188 are used to receive the rollers 198 of the cam roll pin 176. The oppositely disposed plate portions 220 and 222 are also provided with a pair of aligned apertures 226. The apertures 226 are aligned with apertures 228 in the 15 pivotal bracket 132. A pin 23 0 is received in the apertures to provide a pivotal connection between the rotatable bracket 132 and the integrally formed insulated sleeve assemblies 218. The spacing between the oppositely disposed 20 plate portions 22 0 of the insulated sleeves 218 is such that it captures the pivotally mounted bracket 132. Thus, any magnetic repulsion forces generated between the contact arm assemblies due to overcurrent conditions will cause the contact arm assemblies 109 to repel and, in 25 turn, cause the insulated sleeve portions 218 to be forced off the shaft 206. Since the magnetic repulsion forces can cause movement of the contact arm carriers 68 along the shaft 206, these contact arm carriers 68 are welded to the shaft 2 06. The insulated sleeve assemblies 218 may 30 be either molded on the shaft 2 06 or molded separately and affixed to the shaft 2 06 with an adhesive, such as epoxy, and pinned to the shaft 206 by way of one or more metal pins 232 inserted transversely in apertures in the sleeves 218 and the shaft 2 06 to prevent axial movement of the 35 sleeves 218 with respect to the shaft 206. The metal pins 232 are inserted flush into apertures (not shown) in the insulated sleeves 218 and may be covered with an electrically insulating material. 16 5 10 15 20 A rubber stop assembly 234 is provided on each of the outside poles to prevent damage to the cover 24 of the circuit breaker when the contact assemblies 109 are separated from the fixed main contact 32. During relatively high overcurrent conditions, particularly when the contact arm assembly 109 is blown-open by the magnetic repulsion member 118, considerable force is generated. In conventional circuit breakers shock absorbing materials are glued to the inside of the cover to stop or prevent the contact assembly 109 from striking the cover 24. However, in some circumstances, damage to the cover 24 still results. The rubber stop assembly 234 for outside poles is used to prevent the contact assemblies 109 from striking the cover 24. The rubber stop assembly 234 includes a shock absorber 236, spaced away from the cover 24 of the circuit breaker housing 21. By spacing the shock absorber 236 away from the cover 24, damage to the cover 24 is prevented. Advantageously, a preferred aspect of the rubber stop assembly 234 is that it includes a dual purpose bracket 238 with two parallel sets of spaced apart depending arms 240 and 242. The relatively longer set of arms 240 contain aligned apertures 243 at the free end 244 for receiving a pin 246. The shock absorber 236 is generally cylindrical in shape having a center bore with a diameter to allow it to be slidingly received on the pin 246. The pin 246 is slightly longer than the cylindrical shock absorber such that the ends o ! ••£ pp tOni n ! of the pin extends outwardly from the arms 240. This extending portion of the pin is received in integrally molded bores 248 formed in the frame 28 to provide additional support for the rubber stop assembly 234. The relatively shorter set of extending arms 242 are used to provide a pivotal connection for the crossbar assembly 42. A bight portion 219 of the bracket 238 is provided with apertures 250. A barrier plate 252 having a pair of extending 3. (992 r■ 229875 17 apertures 256 which are aligned with the apertures 250 in the bracket 238. The apertures 250 and 256 receive fasteners (not shown) to fasten the rubber stop assembly 234 to the frame of the circuit breaker. 5 Because the operating mechanism 58, including the toggle assembly 60, is adjacent the center pole, a different rubber stop assembly 257 is used for the center pole. More particularly, an elongated metal bar 258 for carrying a shock absorber 260 is provided. The shock 10 absorber 260 is generally an elongated L-shaped member, secured to the elongated metal bar 258. The length of the elongated metal bar is such that it extends beyond the shock absorber 260 and are received in slots (not shown) in oppositely disposed sideplates 262, disposed adjacent 15 the center pole, rigidly fastened to the frame 28. The mounting of the center pole assembly 2 57 is such that it is spaced apart from the operating mechanism 58 to prevent the center pole contact assembly 109 from contacting it. The CT quick change assembly 2 64 allows the main 20 current transformer 54 to be replaced rather quickly and easily either in the factory or in the field. The CT quick change assembly 264 simplifies replacement of the current transformer 54 without requiring extensive dismantling of the circuit breaker. One reason for 25 replacing the current transformer 54 is failure of the current transformer 54. Another reason for replacing the current transformer 54 is the change from one rating to the other rating of a dual rating circuit breaker, such as, in a circuit breaker that has a rating of 1600/2000 30 amperes. More specifically, a current transformer 54 used with the circuit breaker at the 1600 ampere rating would not be suitable for use at the 2000 ampere rating. The CT quick change assembly 264 includes the main current transformer 54 disposed about a load side 35 conductor 4 6 and a removable plate 2 66. The current transformer 54 is a donut-type current transformer which utilizes the load side conductor 4 6 as its primary winding. 229875 18 The main current transformer 54 is disposed in an integrally formed cavity 267 in the frame 28 open on one side to allow removal from the housing 21. The load side conductor is disposed in an integrally formed cavity 5 269 in the frame 28 to allow the load side conductor 46 to be removed from the housing 21 in a direction parallel to its longitudinal axis. In order to remove the current transformer 54 from the housing 21, the removable plate 266 is removed. After the plate 2 66 is removed, it is 10 necessary to unscrew six fasteners 48 to uncouple the load side conductor 46. After these bolts are removed, four more fasteners 52 have to be removed to uncouple the stab 50 from the load side conductor 46. Once the stab 50 is uncoupled from the load side conductor 46, the conductor 15 46 can be slid out in a direction parallel to its longitudinal axis. After the conductor 4 6 is removed, the current transformer 54 can then be removed from the circuit breaker housing 21 and replaced with a different current transformer. To replace the current transformer 20 54, the steps are simply reversed. Thus, it should be clear that a quick change CT assembly has been disclosed which allows for a quick and easy replacement of current transformers in the field. A combination barrier and auxiliary current 25 transformer board 268 is provided. This board 268 has several purposes. One purpose is to provide a barrier to prevent contact with the circuit breaker internal components. More specifically, the board 268 closes an open portion 271 of the housing 21. Another purpose is to 3 0 provide means for mounting auxiliary transformers 27 0. A third purpose is to provide a means to connect the auxiliary transformers 270 to the main current transformer 54 and the electronic trip unit. Lastly, the combination barrier and auxiliary CT board 268 provides means for 3 5 venting of the heat generated within the circuit breaker 20 to the atmosphere. The combination barrier and auxiliary CT board 268 is comprised of an E-shaped printed circuit board 272. 2 2 9 8 7 5 19 The printed circuit board 272 is received in oppositely disposed slots 274 formed in the side walls 276 of the base 22. The bottom of the printed circuit board 272 rests on top of a vertically standing leg 278 portions of 5 the frame 28. The E-shaped printed circuit board 272 is disposed between the latch assembly 82 and the open portion 271 of the housing 21. The printed circuit board 272 contains a pair of spaced apart slots 282 which define its E-shape. The slots 282 are adapted to receive 10 vertically standing side walls 284 formed in the frame 28. Three auxiliary transformers 270 are provided; one for each pole. The auxiliary transformers 270 have full primary and full secondary windings and are used to step down the current applied to the electronic trip unit. 15 More specifically, the secondary winding of each of the main current transformers 54 is applied to the primary winding of a corresponding auxiliary current transformer 270. The secondary windings of the auxiliary transformers 270 are then applied to the electronic trip unit. 20 The printed circuit board 27 2 is used to replace a wiring harness between the auxiliary transformers 272 and the electronic trip unit. More particularly, an electric circuit is provided on the printed circuit board 270 for the electrical connections required between the 25 primary windings of the auxiliary transformers 272 and the secondary windings of the main current transformer 54. The electric circuit is formed on the printed circuit board 272 in a conventional manner. A main connector 286 is provided in the upper right-hand corner of the printed 30 circuit board 272. This connector 286 is electrically connected to the secondary windings of the auxiliary current transformers 272 by way of the electric circuitry formed on the printed circuit board 272. A wiring harness having a connector at both ends (not shown) is then used 35 to connect the printed circuit board 272 to the electronic trip unit. The auxiliary transformers 270 are mounted directly to the printed circuit board 272. secondary connectors 288 are disposed adjacent each of the auxiliary 22 9 8 7 5 20 transformers 270 on the printed circuit board 272. These secondary connectors 288 are connected to the primary windings of the auxiliary transformers 270. In order to connect each of the primary windings of the auxiliary 5 transformers 272 to the secondary windings of the main auxiliary transformers 54, another cable (not shown) is provided having a connector at one end connects the main current transformers 54 to the board 270. Venting holes 290 are provided in the extending 10 leg portions 292 of the printed circuit board 270. These vent holes allow venting of heat generated in the housing 21 to be vented to the atmosphere. The combination barrier and auxiliary CT board 268 thus simplifies assembling of a circuit breaker thus 15 reducing manufacturing costs and simplifies the internal wiring of the circuit breaker 20. A modular option deck assembly is provided which facilitates attachment of various options, such as an undervoltage release mechanism, shunt trip and various 20 other options to the circuit breaker. An undervoltage release mechanism functions to open the main contacts 30 automatically when the line voltage falls below a predetermined value. This is done to prevent certain loads, such as motors, from operating at a reduced voltage 25 which can cause overheating of the motor. An example of an undervoltage release mechanism is disclosed in the specification of U.S. Patent No. 4,489,295. A shunt trip device (not shown) is essentially comprised of a solenoid having a reciprocally mounted plunger disposed adjacent 30 the trip bar 98. The shunt trip device allows the circuit breaker 20 to be tripped from a remote location. Neither the undervoltage release mechanism nor the shunt trip device are required for all circuit breakers 20. These items are custom items and are generally factory in-35 stalled. In order to reduce the manufacturing time ami cost of adding such custom items to the circuit breakers 20 during fabrication, an option deck assembly 294 Is provided. The option deck assembly 294 includM a $»s 5 10 15 20 25 30 rectangular plate disposed under the circuit breaker cover 24 carried by the frame 2 8 having an aperture 296 to allow communication with the trip bar 98. The plate 294 also includes a plurality of sets of slots 298 for receiving a plurality of downwardly extending L-shaped arms 300 integrally formed with a bracket 302. A plurality sets of slots 298 in the bracket 302 for receiving the arms 300 allow cooperation with the L-shaped arms 300 allow the various options to be secured to the rectangular plate 294 to prevent movement in a direction perpendicular to the plane of the plate 294 and alignment with the trip bar 98. The L-shaped arms 300 are provided on diametrically opposite portions of the bracket 302. A plurality of sets of slots 298 are shown. The bracket 3 02 is adapted to be received into any set of diametrically opposite slots 304, 3 06 or 3 08 to allow up to three options, for example, to be provided in a given circuit breaker 2 0. The bracket 302 is provided with a plurality of apertures 310 to allow the options to be attached to the bracket 3 02 by way of a plurality of fasteners (not shown). Grooves 312 are provided in the plate 294, aligned with the apertures 310 in the bracket 302. These grooves 312 provide space for the fasteners used to attach the option to the bracket 3 02 to allow the bracket 3 02 to be slidingly received onto the plate 294. The various options each have a downwardly extending lever (not shown) adapted to engage the trip bar 98 to cause the circuit breaker 2 0 to trip. After the option is assembled to the bracket 3 02, the downwardly extending levers extend downwardly from the rear edge of the bracket 302 through the aperture 29 6 to communicate with the trip bar 98. The brackets 302 are then secured in place. Thus, it should be clear that the option deck assembly allows the customizing of a circuit breaker rather easily and quickly. </div>

Claims

<div class="application article clearfix printTableText" id="claims"> -22- ?2 9 67 WHAT WE CLAIM IS:

1. A circuit breaker comprising a housing having a base portion and a cover portion, one or more pairs of separable contacts disposed in said base portion, an operating mechanism including a trip bar for actuating said separable contacts, a modular option deck disposed adjacent said trip bar having an aperture for allowing communication with said trip bar, sets of slots integrally formed in said deck, a bracket having depending arms slidingly received in a selected set of said set of slots, and an option with an extending actuation lever mounted on the bracket, said extending actuation lever being in communication with the trip bar through said aperture.

2. A circuit breaker as claimed in claim 1, wherein each set of slots contains two slots and the bracket has two arms.

3. A circuit breaker as claimed in claim 2, wherein said two slots of each set of slots are disposed diametrically opposite each other.

4. A circuit breaker as claimed in any one of claims 1 to 3, wherein said depending arms extend downwardly, and are L-shaped.

5. A circuit breaker as claimed in claim 4, wherein said downwardly extending arms are disposed diametrically opposite each other.

6. A circuit breaker as claimed in claim 4 or 5, wherein said downwardly extending arms are integrally formed with said bracket. . •••'... ?29 23

7. A circuit breaker as claimed in claim 1, wherein said option deck is integrally molded from a non-conductive material.

8. A circuit breaker, including a modular option deck, constructed and adapted for use, substantially as hereinbefore described and illustrated with reference to the accompanying drawings. WESTINGHOUSE ELECTRIC CORPORATION By their attorneys HENRY HUGHES LTD Per 2 2 APft 1992 r </div>