Dual Contactor Electrical Panel Assembly, System, and Method

Abstract

The present invention provides a panel assembly for harsh and / or hazardous environments. The panel assembly includes a main circuit breaker assembly, a first sub-panel assembly, and a second sub-panel assembly. The first sub-panel assembly includes a first contactor assembly and a first branch circuit breaker assembly, the first branch circuit breaker assembly being electrically connected to the first contactor assembly and configured to be electrically connected to a first group of loads. The first contactor assembly is configured to simultaneously turn on and off all of the loads in the first group of loads. The second sub-panel assembly is electrically connected in parallel to the first sub-panel assembly and includes a second contactor assembly and a second branch circuit breaker assembly, the second branch circuit breaker assembly being electrically connected to the second contactor assembly and configured to be electrically connected to a second group of loads. The second contactor assembly is configured to simultaneously turn on and off all of the loads in the second group of loads.

Description

BACKGROUND OF THE INVENTION

[0001] The field of the present invention generally relates to heavy-duty electrical panel assemblies for industrial systems, and more particularly to heavy-duty harsh and / or hazardous environment electrical panel assemblies including dual contactor assemblies.

[0002] Certain types of conventional panel assemblies include contactors for simultaneously switching power circuits connected through the panel. During fault diagnosis, maintenance, and repair, such conventional panels are typically completely shut down via the provided contactors. That is, all loads provided by the panel will be disconnected or shut down via the actuation of the contactors. However, in certain applications, it may be advantageous to use certain loads such as motors or lighting while shutting down other loads, and thus more than one panel is typically utilized to provide different loads, where each panel includes a separate contactor for simultaneously switching the loads connected to each panel. In addition, in addition to the panel itself, conventional panel assemblies also include a housing and contactor assemblies, one housing for each contactor assembly, and this combination requires a large footprint and increased installation costs.

[0003] While known panel assemblies of the above type are satisfactory in many cases in some applications, they still have drawbacks and thus need improvement. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] Non-limiting and non-exhaustive embodiments are described with reference to the following drawings, in which like reference numerals refer to like parts throughout the various views unless otherwise specified.

[0005] Figure 1 is a schematic view of an exemplary panel assembly.

[0006] Figure 2 is Figure 1 an exploded view of an exemplary embodiment of the panel assembly shown.

[0007] Figure 3A is Figure 2 a partial front view of the panel assembly shown without the housing.

[0008] Figure 3B is Figure 3A a perspective view of a portion of the panel assembly shown.

[0009] Figure 3C is Figure 3A a circuit diagram of the panel assembly shown.

[0010] Figure 4 is a flowchart showing an exemplary method of using Figures 1 - 3C the panel assembly shown to assemble an electrical component. DETAILED DESCRIPTION

[0011] Exemplary embodiments of the panel assembly disclosed herein utilize a dual contactor assembly integrated within the panel assembly to provide heavy-duty performance in harsh and / or hazardous environments. Each contactor assembly turns on or off a separate set of loads within the same panel assembly, eliminating the need for a conventionally provided second panel assembly and also eliminating a separately provided housing for the contactors as conventionally provided.

[0012] Power systems sometimes operate in hazardous environments, presenting a risk of explosion due to the ignition of surrounding gases or vapor dusts, fibers, or flying dust. Such hazardous environments may occur, for example but not limited to, in refineries, petrochemical plants, grain elevators, wastewater treatment facilities, and / or other industrial facilities where unstable conditions are generated in the surrounding environment, increasing the risk of fire or explosion. The temporary or continuous presence of combustible gases, combustible vapors, combustible dusts, or other flammable substances in the air poses a significant challenge to the overall safety and reliable operation of these facilities, including but not limited to the safe operation of the power system itself. In some cases, conventional circuit protection devices may generate ignition sources during normal operation and electrical faults. Therefore, many standards regarding the use of electrical products in explosive environments have been promulgated based on the assessment probability of explosion or fire risk to enhance safety in hazardous locations.

[0013] For example, Underwriter’s Laboratories (UL) standard UL 1203 specifies the standards for electrical equipment for explosion protection and dust combustion prevention in hazardous locations. Explosion-proof and dust combustion-proof enclosures can be used to encapsulate or house electrical products. In combination with appropriate explosion-proof and dust combustion-proof enclosures, electrical equipment manufacturers can obtain UL certification, demonstrating compliance with the rating standards applicable to hazardous locations. UL certification is an important aspect of a manufacturer's ability to successfully introduce products to the North American market or any other market that accepts UL standard 1203.

[0014] The National Electrical Code (NEC) in the United States typically classifies hazardous locations by class and division. Class I locations are those where combustible vapors and gases may be present. Class II locations are those where combustible dusts are present. Class III locations are those that become hazardous due to the presence of ignitable fibers or flyings. Class I, Division 1 covers locations where combustible gases or vapors may be present under normal operating conditions, during frequent repair or maintenance operations, or where a malfunction or incorrect operation of process equipment may also cause an electrical device to malfunction simultaneously. Division 1 presents a greater explosion risk than, for example, Division 2, where combustible gases or vapors are typically handled in a closed system, confined within a suitable enclosure, or generally prevented by active mechanical ventilation.

[0015] The International Electrotechnical Commission (IEC) also classifies hazardous locations as Class I, Division 0, Division 1, or Division 2, which represent locations where combustible gases or vapors are present in the air in quantities sufficient to produce an explosive or flammable mixture. As defined by the IEC, a Class I, Division 0 location is one where combustible gases or vapors in ignitable concentrations are continuously present or present for long periods of time. A Class I, Division 1 location is one where combustible gases or vapors in ignitable concentrations may be present due to maintenance or repair operations, or due to leakage or possible release of combustible gases or vapors in ignitable concentrations, or is a location adjacent to a Class I, Division 0 location from which vapors in ignitable concentrations may be transmitted.

[0016] Since electrical devices (such as those described below) can be ignition sources in some cases, explosion-proof, flame-retardant, or ignition-resistant enclosures are typically provided in NEC Division 1 or Division 2 locations and / or IEC Zone 1 or Zone 2 locations to house electrical devices that pose a risk of ignition. In this document, the term "explosion-proof" or "flame-retardant" refers to an enclosure that is designed to contain an internal explosion of a specified combustible vapor-air mixture.

[0017] In addition to the hazardous locations discussed above, so-called harsh locations also require specific attention to the design of the panel assemblies used with them. Harsh locations may require corrosive elements, etc. in the atmospheric environment, and harsh locations are not necessarily explosive and / or are subject to temperature cycling, pressure cycling, vibration, and / or mechanical shock forces that are not normally present in non-harsh operating environments. Of course, some locations are inherently both harsh and hazardous, and in these locations, panel assemblies are advantageously employed, and thus the panel assembly is a panel assembly designed for a variety of operating conditions for which typical panel assemblies for other uses are unsatisfactory.

[0018] Figure 1 A schematic diagram of an exemplary heavy-duty harsh and / or hazardous environment panel assembly 100 is shown. In the exemplary embodiment shown, the panel assembly 100 includes a main circuit breaker assembly 102, a first contactor assembly 104a and a second contactor assembly 104b, and a first branch circuit breaker assembly 106a and a second branch circuit breaker assembly 106b. The panel assembly 100 may also include line-side terminals 108 that are configured to be electrically connected to a power source 110. The power source 110 may be an alternating current (AC) power source (such as a three-phase AC power source) or a direct current (DC) power source. The main circuit breaker assembly 102 is electrically connected to the line-side terminals 108 and is configured to turn the entire panel assembly 100 on or off as needed, regardless of the operating positions of the first contactor assembly 104a and the second contactor assembly 104b or any secondary circuit breakers or switches associated with the first branch circuit breaker assembly 106a and the second branch circuit breaker assembly 106b.

[0019] In an exemplary embodiment, a first contactor assembly 104a and a second contactor assembly 104b are electrically connected in parallel with each other and are each electrically connected to a main circuit breaker assembly 102 in a split bus configuration. The first contactor assembly 104a and the second contactor assembly 104b each include one or more contactors 304 (as Figure 3C shown). The contactors 304 can be manually opened or closed and / or can be automatically opened or closed as needed by a photoresistor, a timer, another switch, or a controller.

[0020] In an envisioned embodiment, the first contactor assembly 104a is further electrically connected to a first branch circuit breaker assembly 106a, which is configured to control a first group of loads 112a. The first branch circuit breaker assembly 106a includes one or more branch circuit breakers 113 (as Figures 2 - 3C shown). Each branch circuit breaker 113 is electrically connected to one or more loads in the first group 112a and is configured to individually open or close the connected loads. The second contactor assembly 104b is further electrically connected to a second branch circuit breaker assembly 106b, which includes one or more branch circuit breakers 113 that are configured to individually open or close the second group of connected loads 112b.

[0021] In an exemplary embodiment, a first sub-panel assembly 138a and a second sub-panel assembly 138b (also see Figure 3C ) are formed in a panel assembly 100. The first sub-panel assembly 138a includes the first contactor assembly 104a and the first branch circuit breaker assembly 106a. The second sub-panel assembly 138b includes the second contactor assembly 104b and the second branch circuit breaker assembly 106b. The two sub-panel assemblies are shown herein only as examples. The panel assembly 100 can include more than two sub-panel assemblies 138a, 138b. In other words, the panel assembly 100 can include more than two contactor assemblies and more than two branch circuit breaker assemblies, and each of the contactor assemblies is used to open or close a separate group of loads.

[0022] In operation, the first contactor assembly 104a and the second contactor assembly 104b are used to turn on or off one half of the panel assembly 100 by simultaneously connecting or disconnecting the entire branch breaker assemblies 106a, 106b. For example, if a user wants to turn on or off all of the loads in the first set of loads 112a simultaneously, the user can use the first contactor assembly 104a to perform this operation rather than turning on or off each of the individual branch breakers 113 in the first branch breaker assembly 106a one by one. Similarly, the user can use the second contactor assembly 104b to turn on or off all of the loads in the second set of loads 112b simultaneously rather than turning on or off the individual breakers in the second branch breaker assembly 106b. In this way, the first set of loads 112a and the second set of loads 112b can be turned on and off more quickly via the respective contactor assemblies 104a, 104b as compared to turning on or off each of the individual branch breakers 113 in the branch breaker assemblies 106a, 106b. During fault diagnosis, repair, and maintenance procedures, a relatively safe and convenient environment is also provided by turning on one set of loads (e.g., the first set of loads 112a) via one of the contactor assemblies (e.g., the first contactor assembly 104a) while turning off another set of loads (e.g., the second set of loads 112b) via the other contactor assembly (e.g., the second contactor assembly 104b).

[0023] In an envisioned embodiment, the panel assembly 100 is adapted for use in harsh and / or hazardous environments such as for lighting, motor applications, and other electrical system requirements. In harsh and / or hazardous environments, all of the loads powered by the panel assembly should not be disconnected together because certain loads such as motors or lighting need to be turned on during fault diagnosis, maintenance, and repair. The panel assembly 100 can be specifically configured for Class I, Division 2 hazardous environments. However, the panel assembly 100 can also be used in non-hazardous environments as needed.

[0024] Figure 2It is an exploded view of the panel assembly 100. The panel assembly 100 may further include a mounting plate 114 on which electrical components of the panel assembly 100 such as the main circuit breaker assembly 102, the first contactor assembly 104a and the second contactor assembly 104b, and the first branch circuit breaker assembly 106a and the second branch circuit breaker assembly 106b are mounted. In an exemplary embodiment, the panel assembly 100 may be divided into a main panel 116 and a branch panel 118. The main panel 116 may include the main circuit breaker assembly 102 and the first contactor assembly 104a and the second contactor assembly 104b. The branch panel 118 may include the first branch circuit breaker assembly 106a and the second branch circuit breaker assembly 106b. The panel assembly 100 may further include a main panel blanking face 120. The main panel blanking face 120 may be used to cover at least a portion of the main panel 116. The main panel blanking face may further include one or more slots 122 that allow access to the main circuit breaker assembly 102 to turn on or off the main circuit breaker assembly 102 when the main panel blanking face is placed on the main panel 116. The panel assembly 100 may further include a branch panel blanking face 124 for covering at least a portion of the branch panel 118. The branch panel blanking face 124 may further include one or more slots 122 for accessing the first branch circuit breaker assembly 106a or the second branch circuit breaker assembly 106b.

[0025] In an exemplary embodiment, the panel assembly 100 may further include a housing 126 for enclosing the main panel 116 and the branch panel 118. If the main panel blanking face 120 and the branch panel blanking face 124 are used, the housing 126 also encloses the main panel blanking face 120 and the branch panel blanking face 124. Thus, one housing 126 encloses two sets of contactor assemblies 104a, 104b and branch circuit breaker assemblies 106a, 10b. Compared to a conventional panel assembly in which two housings are used to separately enclose the branch circuit breaker assemblies plus a separate housing for each contactor connected to each panel, the conventional panel assembly occupies significantly more space than the panel assembly 100, not to mention that it is more expensive to provide and install the components in terms of materials and labor.

[0026] Figure 3A and Figure 3B are a front view and a perspective view, respectively, of the panel assembly 100 without the housing 126. Figure 3C is a circuit diagram of the panel assembly 100. The ratings of the electronic components included in Figure 3C are exemplary only and may be higher or lower in other embodiments. In an exemplary embodiment, the panel assembly 100 is configured to be electrically connected to a three-phase AC power supply via lines L1, L2, and L3 (see Figure 3C ). The connection to the three-phase AC power supply is used as an example only herein. The panel assembly 100 may be connected to an AC power supply with other distribution configurations or to a DC power supply.

[0027] In an exemplary embodiment, the main circuit breaker assembly 102 includes three circuit breakers 302, each for each phase of a three-phase power supply, such as Figure 3C shown as L1, L2, L3. The first contactor assembly 104a and the second contactor assembly 104b each include three contactors 304 connected downstream from the main circuit breaker assembly 102, again each for each phase. The first branch circuit breaker assembly 106a and the second branch circuit breaker assembly 106b are connected downstream from the first contactor assembly 104a and the second contactor assembly 104b, and in the example shown, each branch circuit breaker assembly includes three branch circuit breakers 113. Each phase of the branch circuit breaker assemblies 106a, 106b may include more than one branch circuit breaker 113. Each branch circuit breaker 113 may be electrically connected to one or more loads, such as Figure 3C the lighting loads shown. The panel assembly 100 may also include one or more power distribution modules (PDBs) 306 that serve as auxiliary power connectors for electrical devices. In the depicted example, the PDB 306 is used to distribute power from a single input power source to multiple downstream devices. For example, for each phase L1, L2, or L3, the PDB 306 receives a power supply from line L1, L2, or L3 via a single bus 320 and supplies power to the first sub-panel assembly 138a and the second sub-panel assembly 138b via separate buses 322a, 322b. The PDB 306 obviates the need to directly wire each sub-panel assembly 138a, 138b to the power source and provides a clean installation and saves time and money. Although a split bus configuration is shown in Figure 3C , in alternative embodiments, more than two contactors 304 may be provided for each phase and electrically connected to a single main circuit breaker 302 such that, for example, only one-third of the loads connected to the panel may be shut off simultaneously via the corresponding contactors provided. Thus, the number of contactors is scalable to provide any desired partitioning of the loads connected to the contactors while still maintaining a reduced footprint and lower cost relative to conventional panel solutions, as well as eliminating the undesired downtime of the loads required by conventional panel solutions.

[0028] In Figure 3CIn the example shown where the lighting load is connected through the panel, the lighting in one area of a harsh and / or hazardous location can be simultaneously turned off via one of the contactors, while the lighting in another area can be simultaneously turned on, or vice versa. The lighting in one area of a harsh and / or hazardous location can be simultaneously turned on via one of the contactors, while the lighting in another area can be simultaneously turned off. Other loads such as motors can be connected to another panel so that the motor can be turned off for maintenance purposes while the lighting remains on in the area of the motor. Similarly, the internal and external lighting can be coordinated via the panel through a photoelectric unit or a timer to save energy while still providing a safe and well-lit area in the harsh and / or hazardous location when needed. The auxiliary power connection described herein also provides a conventional power connection when needed, which does not require access to another panel that powers other loads such as motors and industrial processes. At the same time, the main circuit breaker assembly 102 can disconnect the entire panel (including the contactor assemblies 104a, 104b in an emergency).

[0029] Figure 4 An exemplary method 400 for assembling an electrical system for a harsh / hazardous environment and connecting a panel assembly such as the above-described panel assembly is shown. Method 400 includes providing 402 a panel assembly. The panel assembly can be any of the above-described panel assemblies 100. Method 400 also includes electrically connecting 404 the panel assembly to a power source. Method 400 also includes electrically connecting 406 a first group of loads to a first branch circuit breaker assembly of the panel assembly. Additionally, method 400 includes electrically connecting 408 a second group of loads to a second branch circuit breaker assembly of the panel assembly.

[0030] Various embodiments of the panel assembly are described herein, including a dual contactor assembly in the panel assembly, thereby shortening the downtime of the electrical assembly, where half of the electrical loads connected to the panel assembly are turned on or off independently of the other half of the loads connected to the panel. In addition, the panel assembly with a dual contactor assembly is only enclosed in one housing, thereby reducing the cost of the panel assembly and the footprint of the panel assembly.

[0031] It is now considered that the beneficial effects and advantages of the inventive concept have been fully shown according to the disclosed exemplary embodiments.

[0032] One embodiment of a panel assembly for harsh and / or hazardous environments is disclosed. The panel assembly includes a main circuit breaker assembly configured to be electrically connected to a power source, a first sub-panel assembly, and a second sub-panel assembly. The first sub-panel assembly includes a first contactor assembly and a first branch circuit breaker assembly. The first contactor assembly is electrically connected to the main circuit breaker assembly. The first branch circuit breaker assembly is electrically connected to the first contactor assembly and is configured to be electrically connected to a first group of loads. The first branch circuit breaker assembly includes one or more branch circuit breakers, and each of the one or more branch circuit breakers is configured to control one or more of the loads in the first group of loads. The first contactor assembly is configured to simultaneously turn on and off all of the loads in the first group of loads. The second sub-panel assembly is electrically connected in parallel to the first sub-panel assembly and includes a second contactor assembly and a second branch circuit breaker assembly. The second contactor assembly is electrically connected to the main circuit breaker assembly. The second branch circuit breaker assembly is electrically connected to the second contactor assembly and is configured to be electrically connected to a second group of loads. The second branch circuit breaker assembly includes one or more branch circuit breakers, and each of the one or more branch circuit breakers is configured to control one or more of the loads in the second group of loads. The second contactor assembly is configured to simultaneously turn on and off all of the loads in the second group of loads.

[0033] Optionally, the panel assembly further includes a housing that encloses the main circuit breaker assembly, the first sub-panel assembly, and the second sub-panel assembly. At least one of the first contactor assembly and the second contactor assembly is turned on and off by a photoresistor. The panel assembly further includes a PDB electrically connected to the main circuit breaker assembly, the first contactor assembly, and the second contactor assembly. The panel assembly further includes a branch panel deadfront that covers at least a portion of the first branch circuit breaker assembly and at least a portion of the second branch circuit breaker assembly, wherein the branch panel deadfront further includes one or more slots that provide access to at least one of the first branch circuit breaker assembly and the second branch circuit breaker assembly. The panel assembly further includes a main panel deadfront that covers at least a portion of the main circuit breaker assembly, wherein the main panel deadfront further includes one or more slots that provide access to the main circuit breaker assembly. The panel assembly further includes a mounting plate, wherein the main circuit breaker assembly, the first sub-panel assembly, and the second sub-panel assembly are mounted on the mounting plate.

[0034] Another embodiment of a panel assembly for harsh and / or hazardous environments is disclosed. The panel assembly includes a first sub-panel assembly, a second sub-panel assembly, and a housing. The first sub-panel assembly includes a first contactor assembly and a first branch circuit breaker assembly. The first contactor assembly is configured to be electrically connected to a power source. The first circuit breaker assembly is electrically connected to the first contactor assembly and is configured to be electrically connected to a first set of loads. The first branch circuit breaker assembly includes one or more branch circuit breakers, and each of the one or more branch circuit breakers is configured to control one or more of the loads in the first set of loads. The first contactor assembly is configured to simultaneously turn on and off all of the loads in the first set of loads. The second sub-panel assembly is electrically connected in parallel to the first sub-panel assembly and includes a second contactor assembly and a second branch circuit breaker assembly. The second contactor assembly is configured to be electrically connected to a power source. The second branch circuit breaker assembly is electrically connected to the second contactor assembly and is configured to be electrically connected to a second set of loads. The second branch circuit breaker assembly includes one or more branch circuit breakers, and each of the one or more branch circuit breakers is configured to control one or more of the loads in the second set of loads. The second contactor assembly is configured to simultaneously turn on and off all of the loads in the second set of loads. The housing encapsulates the first sub-panel assembly and the second sub-panel assembly.

[0035] Optionally, the panel assembly further includes a main circuit breaker assembly electrically connected to the first sub-panel assembly and the second sub-panel assembly, the main circuit breaker assembly being configured to turn on or off the electrical connection to the power source. The panel assembly further includes a PDB electrically connected to the main circuit breaker assembly, the first sub-panel assembly, and the second sub-panel assembly. The panel assembly further includes a main panel deadfront covering at least a portion of the main circuit breaker assembly, wherein the main panel deadfront further includes one or more slots providing access to the main circuit breaker assembly. The panel assembly further includes a mounting plate, wherein the first sub-panel assembly and the second sub-panel assembly are mounted on the mounting plate. At least one of the first contactor assembly and the second contactor assembly is turned on and off by a photoresistor. The panel assembly further includes a branch panel deadfront covering at least a portion of the first branch circuit breaker assembly and at least a portion of the second branch circuit breaker assembly, wherein the branch panel deadfront further includes one or more slots providing access to at least one of the first branch circuit breaker assembly and the second branch circuit breaker assembly.

[0036] An embodiment of a method for assembling an electrical component for a harsh and / or hazardous environment is provided. The method includes providing a panel assembly. The panel assembly includes a main circuit breaker assembly configured to be electrically connected to a power source, a first sub-panel assembly, and a second sub-panel assembly. The first sub-panel assembly includes a first contactor assembly and a first branch circuit breaker assembly. The first contactor assembly is electrically connected to the main circuit breaker assembly. The first branch circuit breaker assembly is electrically connected to the first contactor assembly and is configured to be electrically connected to a first set of loads. The first branch circuit breaker assembly includes one or more branch circuit breakers, and each of the one or more branch circuit breakers is configured to control one or more of the loads in the first set of loads. The first contactor assembly is configured to simultaneously turn on and off all of the loads in the first set of loads. The second sub-panel assembly is electrically connected in parallel to the first sub-panel assembly and includes a second contactor assembly and a second branch circuit breaker assembly. The second contactor assembly is electrically connected to the main circuit breaker assembly. The second branch circuit breaker assembly is electrically connected to the second contactor assembly and is configured to be electrically connected to a second set of loads. The second branch circuit breaker assembly includes one or more branch circuit breakers, and each of the one or more branch circuit breakers is configured to control one or more of the loads in the second set of loads. The second contactor assembly is configured to simultaneously turn on and off all of the loads in the second set of loads. The method further includes electrically connecting the panel assembly to the power source by electrically connecting the main circuit breaker assembly to the power source. The method further includes electrically connecting the first set of loads to the first branch circuit breaker assembly by electrically connecting one of the one or more branch circuit breakers in the first branch circuit breaker assembly to one or more of the loads in the first set of loads. Additionally, the method includes electrically connecting the second set of loads to the second branch circuit breaker assembly by electrically connecting one of the one or more branch circuit breakers in the second branch circuit breaker assembly to one or more of the loads in the second set of loads.

[0037] Optionally, the panel assembly further includes a housing that encapsulates the main circuit breaker assembly, the first sub-panel assembly, and the second sub-panel assembly. At least one of the first contactor assembly and the second contactor assembly is turned on and off by a photoresistor. The panel assembly further includes a branch panel dead front that covers at least a portion of the first branch circuit breaker assembly and at least a portion of the second branch circuit breaker assembly, wherein the branch panel dead front further includes one or more slots that provide access to at least one of the first branch circuit breaker assembly and the second branch circuit breaker assembly. The panel assembly further includes a main panel dead front that covers at least a portion of the main circuit breaker assembly, wherein the main panel dead front further includes one or more slots that provide access to the main circuit breaker assembly. The panel assembly further includes a mounting plate, wherein the main circuit breaker assembly, the first sub-panel assembly, and the second sub-panel assembly are mounted on the mounting plate.

[0038] Although exemplary embodiments of components, assemblies, and systems are described, variations of the components, assemblies, and systems may achieve similar advantages and effects. Specifically, without departing from the described inventive concept, the shapes and geometries of the components and assemblies and the relative positions of the components within the assemblies may differ from those described and depicted. Additionally, in certain embodiments, some of the components within the assemblies may be omitted to accommodate the needs of a particular type of panel assembly or a particular installation, while still providing a cost-effective panel assembly for electrical wiring or cabling.

[0039] This written description uses examples to disclose the invention (including the best mode), and also enables those skilled in the art to practice the invention, including making and using any device or system and performing any incorporated method. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements that are not materially different from the literal language of the claims.

Claims

1. A panel assembly for harsh and / or hazardous environments, the panel assembly comprising: A main circuit breaker assembly configured to be electrically connected to a three-phase power supply; A first sub-panel assembly, the first sub-panel assembly comprising: A first contactor assembly electrically connected to the main circuit breaker assembly; and A first branch circuit breaker assembly electrically connected to the first contactor assembly and configured to be electrically connected to a first group of loads, the first branch circuit breaker assembly including one or more branch circuit breakers, and each of the one or more branch circuit breakers being configured to control one or more of the loads in the first group of loads, wherein the first contactor assembly is configured to simultaneously turn on and off all of the loads in the first group of loads; and A second sub-panel assembly electrically connected in parallel to the first sub-panel assembly and including: A second contactor assembly electrically connected to the main circuit breaker assembly; and A second branch circuit breaker assembly electrically connected to the second contactor assembly and configured to be electrically connected to a second group of loads, the second branch circuit breaker assembly including one or more branch circuit breakers, and each of the one or more branch circuit breakers being configured to control one or more of the loads in the second group of loads, wherein the second contactor assembly is configured to simultaneously turn on and off all of the loads in the second group of loads, A first power distribution module, a second power distribution module, and a third power distribution module, each electrically connected to the main circuit breaker assembly, the first contactor assembly, and the second contactor assembly, respectively, wherein each of the first power distribution module, the second power distribution module, and the third power distribution module is arranged downstream of the main circuit breaker assembly and upstream of both the first contactor assembly and the second contactor assembly, wherein each of the first power distribution module, the second power distribution module, and the third power distribution module is associated with a phase of the three-phase power supply, and wherein each of the first power distribution module, the second power distribution module, and the third power distribution module is configured to receive power through a single bus and distribute the received power to the first contactor assembly and the second contactor assembly through separate buses.

2. The panel assembly according to claim 1, further comprising a housing enclosing the main circuit breaker assembly, the first sub-panel assembly, and the second sub-panel assembly.

3. The panel assembly according to claim 1, wherein at least one of the first contactor assembly and the second contactor assembly is turned on and off by a photoresistor.

4. The panel assembly according to claim 1 further includes a branch panel access surface that covers at least a portion of the first branch circuit breaker assembly and at least a portion of the second branch circuit breaker assembly, wherein the branch panel access surface further includes one or more slots that provide access to at least one of the first branch circuit breaker assembly and the second branch circuit breaker assembly.

5. The panel assembly according to claim 1 further includes a main panel access surface that covers at least a portion of the main circuit breaker assembly, wherein the main panel access surface further includes one or more slots that provide access to the main circuit breaker assembly.

6. The panel assembly according to claim 1 further includes a mounting plate, wherein the main circuit breaker assembly, the first sub-panel assembly, and the second sub-panel assembly are mounted on the mounting plate.

7. A panel assembly for harsh and / or hazardous environments, the panel assembly comprising: A first sub-panel assembly, the first sub-panel assembly comprising: A first contactor assembly configured to be electrically connected to a three-phase power supply; and A first branch circuit breaker assembly electrically connected to the first contactor assembly and configured to be electrically connected to a first group of loads, the first branch circuit breaker assembly including one or more branch circuit breakers, and each of the one or more branch circuit breakers being configured to control one or more of the loads in the first group of loads, wherein the first contactor assembly is configured to simultaneously turn on and off all of the loads in the first group of loads; A second sub-panel assembly electrically connected in parallel to the first sub-panel assembly, the second sub-panel assembly comprising: A second contactor assembly configured to be electrically connected to the three-phase power supply; and A second branch circuit breaker assembly electrically connected to the second contactor assembly and configured to be electrically connected to a second group of loads, the second branch circuit breaker assembly including one or more branch circuit breakers, and each of the one or more branch circuit breakers being configured to control one or more of the loads in the second group of loads, wherein the second contactor assembly is configured to simultaneously turn on and off all of the loads in the second group of loads; A housing that encapsulates the first sub-panel assembly and the second sub-panel assembly; A first power distribution module, a second power distribution module, and a third power distribution module, each electrically connected to the main circuit breaker assembly, the first contactor assembly, and the second contactor assembly, wherein each of the first power distribution module, the second power distribution module, and the third power distribution module is arranged downstream of the main circuit breaker assembly and upstream of both the first contactor assembly and the second contactor assembly, wherein each of the first power distribution module, the second power distribution module, and the third power distribution module is associated with a phase of the three-phase power supply, and wherein each of the first power distribution module, the second power distribution module, and the third power distribution module is configured to receive power through a single bus and distribute the received power to the first contactor assembly and the second contactor assembly through separate buses.

8. The panel assembly according to claim 7, wherein, The main circuit breaker assembly is electrically connected to the first sub-panel assembly and the second sub-panel assembly, and the main circuit breaker assembly is configured to open or close the electrical connection to the three-phase power supply.

9. The panel assembly according to claim 8, further comprising a main panel dead front, the main panel dead front covering at least a portion of the main circuit breaker assembly, wherein the main panel dead front further comprises one or more slots providing access to the main circuit breaker assembly.

10. The panel assembly according to claim 7, further comprising a mounting plate, wherein the first sub-panel assembly and the second sub-panel assembly are mounted on the mounting plate.

11. The panel assembly according to claim 7, wherein at least one of the first contactor assembly and the second contactor assembly is opened and closed by a photoresistor.

12. The panel assembly according to claim 7, further comprising a branch panel dead front, the branch panel dead front covering at least a portion of the first branch circuit breaker assembly and at least a portion of the second branch circuit breaker assembly, wherein the branch panel dead front further comprises one or more slots providing access to at least one of the first branch circuit breaker assembly and the second branch circuit breaker assembly.

13. A method of assembling an electrical component for a harsh and / or hazardous environment, the method comprising: providing a panel assembly, the panel assembly comprising: a main circuit breaker assembly configured to be electrically connected to a three-phase power supply; a first sub-panel assembly, the first sub-panel assembly comprising: a first contactor assembly electrically connected to the main circuit breaker assembly; and a first branch circuit breaker assembly electrically connected to the first contactor assembly and configured to be electrically connected to a first group of loads, the first branch circuit breaker assembly comprising one or more branch circuit breakers, and each of the one or more branch circuit breakers being configured to control one or more loads in the first group of loads, wherein the first contactor assembly is configured to simultaneously open and close all loads in the first group of loads; and A second sub-panel assembly, the second sub-panel assembly being electrically connected in parallel to the first sub-panel assembly and comprising: A second contactor assembly, the second contactor assembly being electrically connected to the main circuit breaker assembly; and A second branch circuit breaker assembly, the second branch circuit breaker assembly being electrically connected to the second contactor assembly and configured to be electrically connected to a second set of loads, the second branch circuit breaker assembly including one or more branch circuit breakers, and each of the one or more branch circuit breakers being configured to control one or more loads in the second set of loads, wherein the second contactor assembly is configured to simultaneously turn on and off all loads in the second set of loads; and A first power distribution module, a second power distribution module, and a third power distribution module, each being electrically connected to the main circuit breaker assembly, the first contactor assembly, and the second contactor assembly, respectively, wherein each of the first power distribution module, the second power distribution module, and the third power distribution module is arranged downstream of the main circuit breaker assembly and upstream of both the first contactor assembly and the second contactor assembly, wherein each of the first power distribution module, the second power distribution module, and the third power distribution module is associated with one phase of the three-phase power supply, and wherein each of the first power distribution module, the second power distribution module, and the third power distribution module is configured to receive power through a single bus and distribute the received power to the first contactor assembly and the second contactor assembly through separate buses; Connecting the panel assembly to the three-phase power supply by electrically connecting the main circuit breaker assembly to the three-phase power supply; Connecting the first set of loads to the first branch circuit breaker assembly by electrically connecting one of the one or more branch circuit breakers of the first branch circuit breaker assembly to one or more loads in the first set of loads; and Connecting the second set of loads to the second branch circuit breaker assembly by electrically connecting one of the one or more branch circuit breakers of the second branch circuit breaker assembly to one or more loads in the second set of loads.

14. The method according to claim 13, wherein the panel assembly further includes a housing that encloses the main circuit breaker assembly, the first sub-panel assembly, and the second sub-panel assembly.

15. The method according to claim 13, wherein at least one of the first contactor assembly and the second contactor assembly is turned on and off by a photoresistor.

16. The method according to claim 13, wherein the panel assembly further includes a branch panel blanking surface that covers at least a portion of the first branch circuit breaker assembly and at least a portion of the second branch circuit breaker assembly, and the branch panel blanking surface further includes one or more slots that provide access to at least one of the first branch circuit breaker assembly and the second branch circuit breaker assembly.

17. The method according to claim 13, wherein the panel assembly further includes a main panel dead-front surface that covers at least a portion of the main circuit breaker assembly, and wherein the main panel dead-front surface further includes one or more slots that provide access to the main circuit breaker assembly.

18. The method according to claim 13, wherein the panel assembly further includes a mounting plate, and wherein the main circuit breaker assembly, the first sub-panel assembly, and the second sub-panel assembly are mounted on the mounting plate.

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