Abstract:
A power intervening and management panel has a low voltage power supply electrically coupled to a low voltage circuit, a power module array having a plurality of power contactor modules where each has a power contactor with a power load input and a power load output switchable between a closed and an open position and a low voltage switch operably connected thereto for switching between the closed and the open position, a low voltage signal relay module for transmitting a low voltage output signal to one of a direct digital controller and a digital timer, and an enclosure containing the low voltage power supply, the power module array and the low voltage signal relay module.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to electrical power systems. Particularly, the present invention relates to electrical power control systems. 
     2. Description of the Prior Art 
     Conventional electrical circuit panel boards such as those used to control lighting circuits include standard electrical-mechanical breakers that control various circuits and/or certain electrical devices attached to those circuits. To energize the circuit, the circuit breaker must be switched on. Circuit breakers found in conventional circuit panel boards are typically not designed for switching purposes. Operating those circuit breakers manually as a means of switch control is not recommended by the manufacturers and certainly not a realistic means of proper energy management. 
     Building and/or energy management systems have been employed for as long as commercial buildings have existed. The earliest and simplest systems included the use of physical manpower to load coal into coal fired boilers or opening water pipe valves manually with the use of a handle to enable heated water to flow through a radiator circuit. The modern understanding of the phrase building management systems means the use of complex electronic devices that are capable of retaining data for the purposes of managing services such as power, lighting, heating and so on. 
     Typically, a building/energy management system is a computer-based control system installed in buildings that controls and monitors the building&#39;s mechanical and electrical equipment such as ventilation, lighting, power systems, fire systems, and security systems. The earlier systems included software and hardware where the software was usually proprietary. New vendors, however, are producing systems that integrate using Internet protocols and more open standards. 
     A building/energy management system is most common in a large building. Systems linked to a building/energy management system typically represent 40% of a building&#39;s energy usage; if lighting is included, this number approaches 70%. Building/energy management systems are a critical component to managing energy demand. Improperly configured building/energy management systems are believed to account for 20% of building energy usage, or approximately 8% of total energy usage in the United States. 
     As well as controlling the building&#39;s internal environment, building/energy management systems are sometimes linked to access control (turnstiles and access doors controlling who is allowed access and egress to the building) or other security systems such as closed-circuit television (CCTV) and motion detectors. Fire alarm systems and elevators are also sometimes linked to a building/energy management system. For example, if a fire is detected by the system then the system could shut off dampers in the ventilation system to stop smoke spreading and/or send all the elevators to the ground floor and park them to prevent people from using them in the event of a fire. 
     Building/energy management systems are usually delivered as fully integrated systems and services through companies such as Siemens, Honeywell, Johnson Controls, Trend Controls, Schneider Electric, Trane and others. Independent services companies use solutions from companies such as Rockwell Automation, KMB systems, BBP Energies, Delta, Distech, Circon and KMC controls. Some of the newer systems allow control of facility-wide systems such as boilers, air handling units and cooling towers via a graphical user interface at one or more workstations in the building or via a web browser over the Internet. 
     A building/energy management system includes controllers, various communications devices and a full complement of operational software necessary for a fully functioning and integrated control system. 
     Currently, building automation and energy management systems that also control facility lighting systems require an integration component that consists of electronic circuit breakers and associated integrated software components. The integrated software components are complex, often proprietary in nature and expensive to install in order to incorporate and integrate lighting control into the building automation and energy management system. 
     Electronic circuit breaker panel boards are available from various manufacturers. Unfortunately, the material and labor costs associated with the installation of the electronic panel boards along with the integration of the electronic circuit board modules for communicating with the energy management system components of various manufacturers is often a financial barrier of entry for businesses that have a desire to better manage their lighting utility consumption more realistically and appropriately for medium to small-size buildings. 
     Therefore, what is needed is a system and method that is easy to install and affordable. What is also needed is a system and method that accomplishes similar economic benefits as the expensive and more complex electronic breaker panels and systems. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a system and method that is affordable for use in medium to small-size buildings and is easy to install. 
     The present invention achieves these and other objectives by providing an electrical power management system. The electrical power management system includes a power intervening panel. One embodiment of the panel intervening panel includes a low voltage power supply having a low voltage output electrically coupled to a low voltage circuit and a power load input, a power module array having a plurality of power contactor modules wherein each of the plurality of power contactor modules has a power contactor with a power load input and a power load output switchable between a closed and an open position and a low voltage switch operably connected to the power contactor for switching the power contactor between the closed and the open position, a low voltage signal relay module having a plurality of signal couplings wherein a primary coupling is a low voltage signal output connected to the low voltage power supply for transmitting a low voltage output signal to a direct digital controller and wherein a secondary coupling is a low voltage signal input for receiving the low voltage output signal from the direct digital controller, the secondary coupling being electrically coupled to the low voltage switch of one of the plurality of power contactor modules, and an enclosure containing the low voltage power supply, the power module array and the low voltage signal relay module. 
     In another embodiment of the power intervening panel, the panel further includes a first fuse connected in series within the low voltage circuit. 
     In a further embodiment of the power intervening panel, the panel further includes a second fuse connected in series with the power load input. 
     In yet another embodiment of the electrical power management system, the system further includes a direct digital controller having a low voltage controller input electrically coupled to the primary coupling of the low voltage signal relay module, a low voltage controller output switchable between an on mode and an off mode and electrically coupled to the secondary coupling of the low voltage signal relay module, and a programmable controller circuit for switching the low voltage controller output between the on mode and the off mode. 
     In another embodiment of the electrical power management system, the system includes a main breaker panel having an electrical main input and a plurality of circuit breakers where one of the plurality of circuit breakers is electrically coupled to the power load input of one of the plurality of power contactor modules. 
     In still another embodiment of the power intervening panel, the power contactor module includes a normally-closed contactor. 
     In another embodiment of the power intervening panel, the panel includes one or more indicators electrically coupled to one or more of the plurality of power control modules, the low voltage power supply and/or the low voltage circuit. 
     In yet another embodiment of the present invention, a digital timer controller system replaces the direct digital controller. The digital timer controller system includes a digital timer controller, an IP-enabled processor module and a plurality of relay modules. 
     In another embodiment of the present invention, there is a method of remotely controlling a power load in a circuit. The method includes obtaining a power intervening panel containing a plurality of power control modules wherein each of the plurality of power control modules has a switchable power contactor with a power load input and a power load output, a low voltage power supply having a low voltage output electrically coupled to a low voltage circuit, and a low voltage relay module having a plurality of signal couplings wherein a primary coupling is electrically coupled to the low voltage power supply for receiving the low voltage output signal and for transmitting the low voltage output signal to a direct digital controller, and a plurality of secondary couplings wherein each of the plurality of secondary couplings is electrically coupled to one of the plurality of switchable power control modules for transmitting the low voltage output signal received from the direct digital controller to one of the plurality of switchable power control modules. The switchable power contactor is electrically switchable between a closed and an open position. The method further includes interrupting a power load of a circuit connected to a circuit breaker in a main breaker panel and connecting the power load from the circuit breaker to the power load input of one of the plurality of switchable power contactors, connecting the circuit to the power load output of the one of the plurality of switchable power contactors, and electrically coupling the low voltage circuit to the direct digital controller. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic, plan view of the present invention showing a power intervening panel, a main breaker panel and a low voltage controller. 
         FIG. 2  is a schematic, plan view of the power intervening panel illustrated in  FIG. 1 . 
         FIG. 3  is a schematic, plan view of the present invention showing a power intervening panel, a main breaker panel and a low voltage controller with an ambient light sensor. 
         FIG. 4  is a schematic, plan view of the present invention showing a power intervening panel, an enlarged low voltage controller with Internet compatible module and an ambient light sensor. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The preferred embodiment(s) of the present invention is illustrated in  FIGS. 1-4 .  FIG. 1  shows a simplified, schematic diagram of a power control system  10 . Power control system  10  includes a power intervening panel  20 , a direct digital controller  60  and a main breaker panel  70 . Power intervening panel  20  includes a power module array  22 , a low voltage power supply  40  and a low-voltage signal power relay module  50 . Power module array  22  includes a plurality of power contactor modules  24  that are normally-closed contactors. Low voltage power supply  40  is electrically coupled to power relay module  50  and to low voltage signal relay module  50 . The electrical coupling between low voltage power supply  40 , power relay module  50  and power module array  22  defines a portion of a low voltage circuit that is used to switch off each of the plurality of power contactor modules  24  of power module array  22 . 
     Main breaker panel  70  is typically connected to a main power line  72 , which may be a 3-wire, conventional 220V AC power line, that feeds into a main breaker  74  and one or more branch circuit breakers  76 . Each branch circuit breaker  76  controls a 220V AC or a 110V AC branch circuit, as is well known. For simplicity,  FIG. 1  does not show the separate phases, ground and neutral lines. One or more of the branch circuit breakers  76  provides power to one of the plurality of power contactor modules  24 . Power contactor modules  24  control power to associated lighting circuits  1 ,  3 . Other electric loads such as ventilation fans, air conditioners, heaters, other environmental equipment, or other equipment in general can be connected to power contactor modules  24  as well. It should be understood that the present invention is equally applicable to systems using different voltages. 
     Each of the plurality of power contactor modules  24  of power module array  22  are in communication with direct digital controller  60 . Direct digital controller  60  is typically a device that processes data that is input from a user interface or a sensor, applies control logic and causes an output action to be generated. The output signal may be sent directly to a controlled device or to other logical control functions and ultimately to the controlled device. The function of direct digital controller  60  is to compare a direct digital controller input (whether originating from a user interface or a sensor) with a set of instructions such as a setpoint, throttling range and action, then produce an appropriate output signal. In the case of lighting control, the input is typically a preset time period for lighting to be on or off. The controlled device in the present invention is the power module array  22 . Examples of direct digital controllers usable in the present invention include controllers manufactured by companies such Honeywell, Johnson Controls, Cresto Electronics, Cisco Systems, Automated Logic, etc. 
     Typically, direct digital controller  60  consists of microprocessor-based controllers with control logic performed by software. Analog-to-digital converters transform analog values into digital signals that a microprocessor can use. Direct digital controller  60  may be a part of a local area network or a wide area network that utilizes routers if TCP/IP (transmission control protocol and internet protocol) is used. Direct digital controller  60  generally includes a plurality of inputs  62  and outputs  64 . In the present invention, the input signal is the low voltage signal from the low voltage power supply  40  of power intervening panel  20 . The outputs of the direct digital controller  60  communicate with the power module array  22  through low voltage signal relay module  50  of power intervening panel  20 . Each pair of inputs  62  and outputs  64  define a low voltage switch that either allows the low voltage signal to pass or not, momentarily or constant depending on the logic result of the microprocessor. 
     Low voltage signal relay module  50  and direct digital controller  60  provide a means for separate control of each of the plurality of power contactor modules  24  of power module array  22 . As shown in  FIG. 1 , each direct digital controller output  64  is electrically coupled to one of the plurality of power contactor modules  24 . It should be understood, however, that one direct digital controller output  64  may control one or more of the power contactor modules  24  and should not be construed as controlling only one power contactor module  24 . 
     Turning now to  FIG. 2 , there is illustrated one embodiment of the power intervening panel  20 . Power intervening panel  20  includes an enclosure  21  that is UL listed (Underwriters Laboratories). Enclosure  21  is typically made of metal and includes a removable or hinged door and an internal mounting panel for mounting power module array  22 , low voltage power supply  40  and low voltage signal relay module  50  thereon. An example of a useable enclosure  21  is a Hoffman enclosure model no. A-20N16ALP available from the Kele Company located in Bartlett, Tenn., USA. 
     Low voltage signal relay module  50  has a relay signal input coupling or first coupling  52  and a plurality of secondary or relay signal output couplings  54 . Relay signal input coupling  52  is electrically coupled to one or more inputs  62  of direct digital controller  60 . Each of the plurality of relay signal output couplings  54  may be electrically coupled to one or more outputs  64  of direct digital controller  60  and one or more power contactor modules  24 . An acceptable low voltage signal relay module  50  is available from ABB, Inc. of Cary, N.C., USA, as model no. M4/6.P-4 mm 2  ground bock with rail contact. 
     Low voltage power supply  40  has a power load input  42  and a low voltage signal output  44 . Low voltage signal output  44  is electrically coupled to relay signal input coupling  52  of low voltage signal relay module  50 . Power load input  42  is electrically coupled to a power load that communicates with one of the branch circuit breakers  76  of main breaker panel  70 . Low voltage power supply  40  is a control transformer that receives a 120V AC and transforms the current to 24V AC. Any number of available power transformers may be used in power intervening panel  20 . An example of a useable low voltage power supply  40  is a Functional Devices, Inc. RIB TR Series control transformer model no. TR100VA001 available from the Kele Company located in Bartlett, Tenn., USA. 
     Power module array  22  has a plurality of power contactor modules  24 . In this embodiment, each power contactor module  24  includes a housing  26  that includes a plurality of normally-closed switches  27  and a low voltage coil  30 . Each switch  27  has a power load input  28  that may be electrically connected to a power load from a branch circuit breaker  76  of main breaker panel  70  and a power load output  29  that provides power to an associated lighting circuit. Low voltage coil  30  has a signal input  32  electrically connected to one of the secondary or relay signal output couplings  54  for receiving a low voltage signal from direct digital controller  60 . Because switches  27  are normally-closed, power connected to the power load input  28  passes directly to the associated lighting circuit. When low voltage coil  30  is energized by receiving a low voltage signal from direct digital controller  60  via low voltage signal relay module  50 , the magnetic contacts inside the normally-closed switches  27  open. Thus, low voltage coil  30  controls the current in a power circuit passing through power control module  24  by either opening or closing switch  27 . Opening the normally-closed switch  27  effectively turns off the power to the associated lighting circuit and consequently turns off the lights and/or equipment on that power circuit. An example of a useable power control module  24  is an AEG Electrolux contactor available as model LS7K-04-G from the Kele Company located in Bartlett, Tenn., USA. 
     To further protect the various components of the present invention, fuses  47  and  48  may be optionally included within the power intervening panel  20 . Fuse  47  is electrically coupled between the power load input  42  and the branch circuit from the main breaker panel  70  protecting low voltage power supply  40  from the main power load. Fuse  48  is electrically coupled between the low voltage output  44  and the direct digital controller  60  protecting low voltage power supply  40  from the direct digital controller  60 . Fuse  47  protects low voltage power supply  40  against surges from the branch circuit that is sending power to power load input  44  while fuse  48  protects low voltage power supply  40  against surges from the direct digital controller  60  that may be caused by a malfunctioning direct digital controller  60 . It is further contemplated that fuses may be optionally and serially included in the low voltage circuit between signal input  32  of power contactor module  24  and the respective contactor output  64  of direct digital controller  60 . 
     Additionally, enclosure  21  may incorporate one or more indicators such as, for example, a plurality of LED lights (not shown) to indicate when power to a circuit is on or off. This could include LED lights to indicate power to individual power load circuits, or to indicate an operational low voltage power supply  40  and/or to indicate a problem with low voltage power, or to indicate a problem with one of the low voltage signal outputs  64  of the direct digital controller  60 , or with the low voltage signal controller input  62 . 
       FIG. 3  illustrates another embodiment of the present invention. In this embodiment, power control system  10  includes power intervening panel  20 , main breaker panel  70 , direct digital controller  60 , and an additional component. The additional component is an ambient light sensor  80 . Light sensor  80  includes a light sensor input  82  and a light sensor output  84 . Light sensor  80  is a relay switch that has a low ambient setting for turning the switch on and a high ambient setting for turning the switch off. In this embodiment, light sensor  80  requires a 24V AC power source, which is supplied by low voltage power supply  40  within power intervening panel  20 . An example of a useable light sensor or photo switch is sold as model no. EM Photo Switch available from the Kele Company located in Bartlett, Tenn., USA. It is contemplated that light sensor  80  is used to override (i.e. short circuit) the low voltage signal passing from low voltage power supply  40  through direct digital controller  60  to power control array  22 . In the present embodiment, light sensor  80  must “short-circuit” the low voltage signal being received by the power control module  24 . This is so in order to turn the power back on to the associated circuit connected to power control module  24  since power control modules  24  incorporate normally-closed switches  27  that open when low voltage coil  30  is energized by the low voltage signal being communicated from direct digital controller  60 . Alternatively, a light sensor  80  requiring a DC voltage source may also be used, however, such a light sensor will be connected to the direct digital controller for the DC voltage required and to interact with the controller program logic software for operating the inputs and outputs  62 ,  64 , respectively, of the 24V AC signal from the low voltage power supply  40 . An example of a DC voltage light sensor or photo switch is sold as model no. MK7-B Series Celestial Ambient Light Sensors available from the Kele Company located in Bartlett, Tenn., USA. It should be understood that the use of power control modules having normally-open switches is also contemplated by the present invention. 
     Turning now to  FIG. 4 , there is illustrated another embodiment of the present invention. In this embodiment, direct digital controller  60  is replaced with an IP-enabled, digital timer system  100 . Digital timer system  100  includes a digital timer controller  150 , an IP-enabled processor module  158  and a plurality of relay modules  155 ,  156 . Digital timer controller  150  generally includes a plurality of inputs  152  and outputs  154  as well as a network communication port  159 . An example of a useable digital timer controller  150  is model no. M2 Modular Direct Digital Universal Controller available from Solidyne Corporation of Rolling Meadows, Ill. In the present invention, the input signal to power and enable digital timer controller  150  is the low voltage signal from the low voltage power supply  40  of power intervening panel  20 . The outputs  154  of the digital timer controller  150  communicate with the low voltage signal relay module  50  of power intervening panel  20  through relay modules  155  and  156 . The output signal from the M2 Controller is a 10V DC signal. 
     Relay module  155 , which is an analog output module, electrically couples to outputs  154  to receive the 10V DC signal from digital timer controller  150  that is controlled (typically, “on” or “off”) by the controller logic programmed into digital timer controller  150 . An example of a useable analog output module  155  is model no. AO-4 Analog Output Module available from Solidyne Corporation of Rolling Meadows, Ill. The AO-4 Analog Output Module has four outputs. 
     Relay module  156 , which is a conversion relay module, is electrically coupled to relay module  155  and receives the 10V DC signal and converts the signal to a 24V AC signal. Relay module  156  has an output  156   b  that is electrically coupled to power contactor module  24  by way of low voltage relay module  50 . An example of a useable conversion relay module  156  is model no. RIBMU2C Pilot Control Relay available from Functional Devices, Inc. of Russiaville, Ind. The RIBMU2C Control Relay has two inputs. Consequently, in the preferred embodiment, each analog output module requires two conversion relay modules in order to couple to all four outputs of the analog output module. 
     IP-enabled processor module  158  is an interface module that connects the network communication port  159  of digital timer controller  150  to the Internet  162  for remote programming of digital timer controller  150  through circuit  160 . An example of a useable IP-enabled processor module  158  is model no. i3 3220 Programmable Network Controller also available from Solidyne Corporation. Digital timer system  100  is less expensive than the more expensive all-inclusive controllers previously discussed while providing all of the functionality required for controlling power intervening panel  20 . An ambient light sensor  80  may optionally be coupled to either the digital timer controller  150  or to the low voltage circuit as shown in  FIG. 4 , all as is previously disclosed. Digital timer system  100  may be incorporated in a separate panel enclosure or within power intervening panel  20 . 
     The advantages of the present invention are numerous. The present invention provides a low-cost alternative to the state-of-the-art power control systems. Unlike other state-of-the-art power control systems, the unique value of the present invention is the cost savings from the ability to use conventional electrical circuit panel boards that include standard electrical-mechanical breakers instead of expensive and complex electronic circuit breakers that require proprietary integration with existing building management systems. Installation time required is also significantly less because of the complexity of wiring state-of-the-art power control systems that incorporate electronic circuit breakers and programmable microprocessor(s). Installation times are on the order of one-third of the time or less than the time required for installing a comparable high-tech power control system. Additionally, any electrician is capable of wiring the power intervening panel  20  of the present invention without requiring special training to understand the programming required to make the high-tech power control system function properly. 
     Although the preferred embodiments of the present invention have been described herein, the above description is merely illustrative. Further modification of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention as defined by the appended claims.