Abstract:
A dynamically configurable electrical distribution system is provided for selectively connecting an electrical power source to load devices. The system comprises an electrical distribution panel and a plurality of switching devices mounted in the panel each electrically connected between an electrical power source and an associated load device for selectively delivering electrical power to the associated load device. A control system is mounted to the panel for controlling operation of the switching devices. The control system comprises a programmed controller for commanding operation of the switching devices. A memory stores configuration information relating to operation of the switching devices. The control system further comprises a user interface device. The program controller is programmed to implement a configuration routine enabling a user to define operation of the switching devices using the user interface. The configuration routine requests basic information to be entered by the user and responsive to the basic system information entered by the user automatically requests only detailed operation information required based on the entered basic system information.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority of provisional application No. 60/826,587 filed Sep. 22, 2006, the contents of which is incorporated by reference herein. 
    
    
     FIELD OF THE INVENTION 
     This invention relates generally to residential and commercial electrical power distribution panels and components, and more particularly, to a system and method for dynamically configuring operation of the power distribution panel during commissioning. 
     BACKGROUND OF THE INVENTION 
     Circuit breaker panels are used to protect electrical circuitry from damage due to an overcurrent condition, such as an overload, a relatively high level short circuit, or a ground fault condition. To perform that function, circuit breaker panels include circuit breakers that typically contain a switch unit and a trip unit. The switch unit is coupled to the electrical circuitry (i.e., lines and loads) such that it can open or close the electrical path of the electrical circuitry. The switch unit includes a pair of separable contacts per phase, a pivoting contact arm per phase, an operating mechanism, and an operating handle. 
     In the overcurrent condition, all the pairs of separable contacts are disengaged or tripped, opening the electrical circuitry. When the overcurrent condition is no longer present, the circuit breaker can be reset such that all the pairs of separable contacts are engaged, closing the electrical circuitry. 
     In addition to manual overcurrent protection via the operating handle, automatic overcurrent protection is also provided via the trip unit. The trip unit, coupled to the switch unit, senses the electrical circuitry for the overcurrent condition and automatically trips the circuit breaker. When the overcurrent condition is sensed, a tripping mechanism included in the trip unit actuates the operating mechanism, thereby disengaging the first contact from the second contact for each phase. Typically, the operating handle is coupled to the operating mechanism such that when the tripping mechanism actuates the operating mechanism to separate the contacts, the operating handle also moves to a tripped position. 
     Switchgear and switchboard are general terms used to refer to electrical equipment including metal enclosures that house switching and interrupting devices such as fuses, circuit breakers and relays, along with associated control, instrumentation and metering devices. The enclosures also typically include devices such as bus bars, inner connections and supporting structures (referred to generally herein as “panels”) used for the distribution of electrical power. Such electrical equipment can be maintained in a building such as a factory or commercial establishment, or it can be maintained outside of such facilities and exposed to environmental weather conditions. Typically, hinge doors or covers are provided on the front of the switchgear or switchboard sections for access to the devices contained therein. 
     In addition to electrical distribution and the protection of circuitry from overcurrent conditions, components have been added to panels for the control of electrical power to loads connected to circuit breakers. For example, components have been used to control electrical power for lighting. 
     One system used for controlling electrical power to loads utilizes a remote-operated circuit breaker system. In such a system, the switch unit of the circuit breaker operates not only in response to an overcurrent condition, but also in response to a signal received from a control unit separate from the circuit breaker. The circuit breaker is specially constructed for use as a remote-operated circuit breaker, and contains a motor for actuating the switch unit. 
     In an exemplary remote-operated circuit breaker system, a control unit is installed on the panel and is hard-wired to the remote-operated circuit breaker through a control bus. When the switch unit of the circuit breaker is to be closed or opened, an operating current is applied to or removed from the circuit breaker motor directly by the control panel. Additional, separate conductors are provided in the bus for feedback information such as contact confirmation, etc., for each circuit breaker position in the panel. The control unit contains electronics for separately applying and removing the operating current to the circuit breakers installed in particular circuit breaker positions in the panel. The panel control unit also has electronics for checking the state of the circuit breaker, diagnostics, etc. One advantage of that system is that the individual circuit breakers can be addressed according to their positions in the panel. 
     Such known remote-operated circuit breaker systems require a user to configure operation, such as programming on and off times and the like. The complexity of the desired operation may prove problematic and time consuming for a user to perform set up procedures. For example, the user must understand complex set up procedures and often configure each switch unit individually. While reference manuals may provide instruction for performing configuration, users tend to avoid use of such manuals. This may result in substantial time spent configuring the system, particularly when it is desired to have features such as common control, use of remote input, individualized scheduling, and the like. 
     The present invention is directed to improvements in configuring electrical distribution systems. 
     SUMMARY OF THE INVENTION 
     In accordance with the invention, there is provided a dynamic setup system and method in an electrical distribution system. 
     There is disclosed in accordance with one aspect of the invention a dynamically configurable electrical distribution system for selectively connecting an electrical power source to load devices. The system comprises an electrical distribution panel and a plurality of switching devices mounted in the panel each electrically connected between an electrical power source and an associated load device for selectively delivering electrical power to the associated load device. A control system is mounted to the panel for controlling operation of the switching devices. The control system comprises a programmed controller for commanding operation of the switching devices. A memory stores configuration information relating to operation of the switching devices. The control system further comprises a user interface device. The program controller is programmed to implement a configuration routine enabling a user to define operation of the switching devices using the user interface. The configuration routine requests basic information to be entered by the user and responsive to the basic system information entered by the user automatically requests only detailed operation information required based on the entered basic system information. 
     It is a feature of the invention that the basic information is selected from a group including panel, breakers, inputs, zones, mapping and schedules. 
     It is another feature of the invention that the user interface device comprises a touch screen display used by the user to enter configuration information. 
     It is still another feature of the invention that the configuration routine generates a series of setup screens to be displayed on the touch screen display. 
     It is still a further feature of the invention that the information requested on each setup screen is dynamically updated based on previous information entered by the user. 
     In accordance with another aspect of the invention, a dynamically configurable electrical distribution system further comprises a plurality of electrical distribution panels with a plurality of switching devices mounted in each panel. The control system is mounted to one of the plurality of panels. 
     There is disclosed in accordance with another aspect of the invention the method for dynamically configuring an electrical distribution system used for selectively connecting an electrical power source to load devices, comprising: providing at least one electrical distribution panel; providing a plurality of switching devices mounted in the panel or panels each electrically connected between an electrical power source and a load device for selectively delivering electrical power to the load device; providing a programmed controller for commanding operation of the switching devices in accordance with a scheduling routine and configuration information stored in a memory; and operating a user interface of the programmed controller to enter the configuration information using a configuration routine enabling a user to define operation of the switching devices using the user interface, the configuration routine requesting basic system information to be entered by the user and responsive to basic system information entered by the user automatically requesting only detailed operation information required based on the entered basic system information. 
     Further features and advantages of the invention will be readily apparent from the specification and from the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an elevation view of a power distribution panel according to the invention; 
         FIG. 2  is a block diagram illustrating pairs of circuit breakers and remote operated devices of the power distribution panel of  FIG. 1 ; 
         FIG. 3  is a block diagram of the power distribution panel of  FIG. 1 ; 
         FIG. 4  is an expanded schematic/block diagram of the power distribution panel of  FIG. 1 ; 
         FIG. 5  is a block diagram of a power distribution system according to an alternative embodiment of the invention; 
         FIG. 6  is a block diagram of a remote operated device according to the invention; 
         FIG. 7  is a flow diagram of a dynamic setup wizard routine implemented in the system controller of  FIG. 4 ; and 
         FIG. 8  is user interface screen used in connection with the dynamic setup wizard routine of  FIG. 6 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     An electrical distribution system, such as an integrated lighting control system, in accordance with the invention permits a user to control power circuits typically used for lighting, as well as circuits for resistive heating or air conditioning, and configure the system using a dynamic setup wizard. Control may include on/off switching, dimming and metering. The electrical distribution system may be as is generally described in U.S. application Ser. No. 11/519,727, filed Sep. 12, 2006, the specification of which is incorporated by reference herein. 
     Referring to  FIG. 1 , a lighting control system in accordance with the invention comprises a lighting control panel  100 . The panel  100  may comprise a Siemens type P 1  panelboard, although the invention is not limited to such a configuration. Line power enters the panel  100  through power source cables  102  connected to a source of power  104 . Line power may, for example, be a three phase 480Y277, 240 or 120 VAC power source, as is conventional. The cables  102  are electrically connected to an input side of a main breaker  106 . The main breaker  106  distributes line power to individual circuit breakers  108  in a conventional manner. How the power is distributed depends on design of the individual circuit breakers  108 , as will be apparent to those skilled in the art. The power is distributed to the line side of individual circuit breakers  108 . The panel  100  may be configured to accept up to forty two individual circuit breakers  108 , although only thirty are shown in the embodiment of  FIG. 1 . Each circuit breaker may be of conventional construction and may be, for example, a Siemens BQD circuit breaker. Each circuit breaker  108  includes a line lug or terminal  108 A receiving power from the main breaker  106  and a load lug or terminal  108 B conventionally used for connecting to a load circuit. 
     For simplicity of description, when a device such as a circuit breaker  108  is described generally herein the device is referenced without any hyphenated suffix. Conversely, if a specific one of the devices is described it is referenced with a hyphenated suffix, such as  108 - 1 . 
     In accordance with the invention, each load circuit to be controlled also has a remote operated device  110 , such as a relay, a meter or a dimmer. The term remote operated device as used herein includes any other devices that controls, monitors or may otherwise be used in a load circuit, in accordance with the invention. While in a preferred embodiment, the remote operated device  110  is a separate component from the circuit breaker  108 , the term “remote operated device” as used herein encompasses devices integral with the circuit breaker. The remote operated devices  110  are also connected to data rails  112 A and  112 B. A panel controller  114  controls the remote operated devices  110  through connections provided via the data rails  112 A and  112 B, as discussed below. 
     The remote operated device  110  includes a housing  110 H encasing an auxiliary set of contacts that can be remotely operated to open and close a lighting circuit. The device  110  is attached to the load side of a circuit breaker  108  within a panel  100  using a conductor tab, i.e., the terminal  110 A, inserted into the breaker lug  108 B. The load terminal  110 B comprises a lug os the same size as the breaker lug  108 B for connecting to a wire to be connected to the load device. The device housing  110 H is configured to mount in a Siemens type P1 panelboard, although the invention is not limited to such a configuration. 
     Referring to  FIG. 2 , a block diagram illustrates four circuit breakers  108 - 1 ,  108 - 2 ,  108 - 3  and  108 - 4 , and respective associated remote operated devices  110 - 1 ,  110 - 2 ,  110 - 3  and  110 - 4 . In the illustrated embodiment, the first device  110 - 1  comprises a relay, the second device  110 - 2  comprises a breaker, the third device  110 - 3  comprises a current transformer, and the fourth device  110 - 4  comprises a dimmer. As is apparent, any combination of these remote operated devices  110  could be used. Each remote operated device  110  includes an input terminal  110 A electrically connected to the associated circuit breaker load terminal  108 B, and an output terminal  110 B for connection to a load device. 
     Referring to  FIG. 3 , a block diagram of the lighting control panel  100  is illustrated. Power from the lines  102  is provided via an isolation transformer  116 , power switch  118  and fuse  120  to a switching power supply  122 . The panel controller  114  comprises an input/output (I/O) controller  124  and optionally a system controller  126 . While the I/O controller  124  and the system controller  126  are described as separate elements, the functionality can be combined into a single controller, as will be apparent. The power supply  122  provides isolated power to all of the control components including the I/O controller  124 , the system controller  126 , and the remote operated devices  110 , see  FIG. 1 , via the data rails  112 A and  112 B. The I/O controller  124  and system controller  126  each have DC-DC converters deriving regulated DC voltage levels as required from the main DC output of the power supply  122 . The power supply  122  also provides 24 volts to the remote operated devices  110 . The system controller  126  is operatively connected to a touch screen  128  and an LCD  130 . 
     In one embodiment of the invention, shown in  FIG. 4 , the panel controller  114  functions as a single panel stand alone system. The I/O controller  124  supplies power and control signals through the rails  112 A and  112 B to the remote operated devices, four of which,  110 - 1 ,  110 - 21 ,  110 - 22  and  110 - 42 , are illustrated. A user interface and high level scheduling and control are provided by the system controller  126 . 
     The I/O controller  124  provides discrete inputs to the controller  114  from dry contact switches, such as wall switches, (not shown) which can be connected to discrete input terminals  140 . The terminals  140  are organized as two inputs and a common. The inputs to the terminals  140  are detected by dry contact I/O logic  142 . A selector logic block  144  generates selector line signals and serial communications to the remote operated devices  110  via the data rails  112 . The logic blocks  142  and  144  are operatively associated with a microprocessor or microcontroller  146 . A TP-UART integrated circuit  148  provides an EIB (European Installation Bus) interface. A connector  149  allows mating directly to the system controller  126  via a cable  150 . 
     The system controller  126  provides the user with an application to implement lighting schedules, organize devices into logical groups, manage the inputs, and obtain status information. The system controller  126  includes a microprocessor  152  operatively connected to a user interface  154  in the form of an integrated touch screen  128  and LCD  130 , see  FIG. 3 . The microprocessor  152  is also connected to memory devices  156  and an ethernet controller  158 . A TP-UART circuit  160  provides an EIB interface while additional interfaces are provided via an analog modem  162  and RS  485  interface circuit  164 . A connector  162  is provided for connection to the cable  150  to transfer information between the system controller  126  and the I/O controller  124 . 
     In another embodiment, shown in  FIG. 5 , multiple lighting control panels  100 - 1 ,  100 - 2  and  100 - 3  are configured to work as a single unit with the first panel  100 - 1  being configured as a master, and the other panels  100 - 2  and  100 - 3  configured as slaves. To configure the first panel  100 - 1  as a master, the system controller  126  is used. The slave panels  100 - 2  and  100 - 3  contain no system controller. Instead, an EIB bus  170  interconnects the I/O controller boards  124 - 1 ,  124 - 2  and  124 - 3 . Overall control for each of the panels is directed by the system controller  126 . 
     Referring again to  FIG. 2 , a data rail  112  is illustrated schematically. The data rail  112  is mechanically attached directly to the interior of the lighting control panel  100 . The data rail  112  comprises a shielded communication bus including a ribbon connector  178  having twenty-five to twenty-nine wires to be routed to the I/O controller  124 . The ribbon connector  178  typically has twenty-six wires, two for power connection, two for ground connection, one for the serial line and up to twenty-one select lines, one for each remote operated device  110 . Each data rail  112  provides a barrier to isolate the class  1  load wires from the class  2  signal wires used to manage the devices  110 . The data rails  112  will connect to each device  110  via a connector that extends out of the device  110 . The wires are connected to lines in the form of traces on a printed circuit board  180 . A power trace  182  provides 24 volt DC power to each remote operated device  110 . A common trace  184  provides a ground to each remote operated device  110 . A serial interface trace  186  provides serial communication to each of the remote operated devices  110 . A plurality of select line traces, four of which  188 - 1 ,  188 - 2 ,  188 - 3  and  188 - 4  are illustrated, are provided, one for each remote operated device  110 . Each remote operated device  110  includes a four wire cable  190  for connection to the data rail  112 . The four wires comprise a select line  191  connected to one of the select traces  188 , a serial interface line  192  connected to the serial interface trace  186 , a neutral wire  193  connected to the common trace  184  and a power wire  194  connected to the power trace  182 . 
     In accordance with the invention, a unique select line is assigned to each breaker  108 /remote operated device  110  pair positioned within the lighting control panel  100 . Select lines are used by the I/O controller  124  to select single remote operated devices  110  to communicate via the serial interface  186  at any given time. For example, when the first select line  188 - 1  is asserted, the first remote operated device  110 - 1  listens for messages on the serial interface line  186 . Conversely, messages on the serial interface line  186  are ignored if the first select line  188 - 1  is not asserted. A response by any of the remote operated devices  110  to a serial command is therefore conditional on whether its particular select line is asserted. The term “asserted”, as used herein, means one state of a signal designated to cause the remote operated device to listen for messages. In a preferred embodiment, the select line has “high” and “low” states, the high state being the asserted state. 
     The remote operated device  110 , in the form of a relay, allows remote switching of an electrical branch load. The device  110  is designed to fit inside a standard electrical panel board with up to forty-two branch circuit breakers  108 . The device  110  is an accessory to a branch circuit breaker  108  allowing repetitive switching of the load without effecting operation of the circuit breaker  108 . 
     The remote operator device  110  requires a means to receive command signals to open or close and to report back successful operation or device status. Also required is a means to drive opening and closing of the switch mechanism contacts. In accordance with the invention, the remote operated device uses two magnetically held solenoids as an actuator device and one electronic circuit board similar to a single pole device. With this design, electronic control circuitry is located inside the switching device itself. Only one circuit is needed to operate both actuators. The use of two magnetically held solenoids or “mag latches” as switching actuators results in very low energy requirements, requires short duration pulses to change position (measured in milliseconds), provides accurate and repeatable timing and requires that the control must reverse voltage polarity. 
       FIG. 6  illustrates a basic block diagram for load switching. The remote operated device  110 , in the form of a relay, includes a control circuit  480  connected to the cable  190 . The control circuit  480  drives a control relay CR having a normally open contact  482  connected between the terminals  110 A and  110 B. A sensor  484  senses status of the relay CR and is connected to the control circuit  480 . As such, the control circuit  480  controls operation of the contact  482  to selectively electrically connect a load L to the breaker  108 , and thus to power the load L. 
     The control circuit  480  comprises a conventional microcontroller and associated memory, the memory storing software to run in the control circuit  480  in accordance with commands received from the I/O controller  124 . 
     The software implemented in the remote operator device control circuit  480  includes various routines. This includes a start up routine executed when the control circuit  480  resets. It reads any data that has been stored in memory that needs to be modified during operations into ram variables. It turns out interrupts and otherwise initialize microcontroller operations and jumps into a status loop function. 
     The status loop function has several objectives. One is to keep the status data up to date to respond to status requests. Another is to run the state machine for the device, such as managing pulse widths and sequencing retry. 
     Pulse widths for open and close are not the same. Also, the pulse width for the open operation is not always the same, it increases by temperature/age/ number of times closed. An open contacts function will set up the sequencer for an open operation placing a start open pulse task and a stop open pulse task into a sequence or queue. The open command is always executed, regardless of the detected position of the contacts, to overcome any failures in detecting the position of the contacts. A close contacts function sets up a sequencer for a close operation replacing a start close pulse task and a stop close pulse task into the sequencer queue. The close command will always be executed, regardless of the detected position, to overcome any failures in detecting the position of the contacts. 
     A communications handler function runs communications protocol over the serial line. The functions include decode command, open, close, send status and send report. A report operation function assembles the data required to respond to a report operation command received on the serial line. 
     Communications from the I/O controller  124  to the remote operated device  110  will be master-slave, with the I/O controller  124  being the master and the devices  110  the slaves. Once the I/O controller application sends an open or closed command, it will not wait for a response from the device  110 . Rather, it hands over to the I/O sequencer queue, to perform a status check at a later time. This allows some time for the device  110  to settle down with its new status. 
     In the case of sending open or closed commands to more than one device  110  at the same time, one open command does the job after the I/O controller  124  enables the respective device select lines. For example, the I/O controller  124  might turn on the select line for devices  110 - 4 ,  110 - 7 ,  110 - 9 , then send out one open command. Devices  110 - 4 ,  110 - 7  and  110 - 9  would all see the open command and attempt to open the mag latch. 
     In accordance with the invention, the system controller  126  provides a user interface application via the touch panel user interface  154  for the user to configure the system. This configuration includes setting up panels, breakers, zones, inputs, I/O mappings, schedules and overrides. 
     To implement the user interface application, the user needs to answer a set of questions and based on the responses required screens are created dynamically and displayed to the user in a step by step process. 
     A lighting control panel  100  may include up to forty-two circuit breakers  108 , and associated remote operated devices  110 , thirty-two digital inputs and two analog inputs. Each control panel  100  includes an I/O controller  124 . A system controller  126  inside one of the panels  100  can control up to seven additional panels, for a total of eight, each having an I/O controller  124 , three of which are shown in  FIG. 5 . The system controller user interface  154  is used to configure various features of these panels  100 . 
     The main configuration features include setting up panels, setting up breakers, setting up inputs, setting up zones, setting input to output mappings and setting up schedules. The complexity of some of these features demand that a particular item can be properly set up only if a different item has already been set up. In accordance with the invention, a dynamic setup wizard routine is used. The number of steps or the number of screens is always dependent on responses to the questions user gives in the preliminary input screen, and subsequent screens. 
       FIG. 7  is a flow diagram of a dynamic setup wizard routine implemented in the system controller  126 , see  FIG. 4 .  FIG. 8  is a user interface screen displayed on the display screen  130  during configuration. 
     The configuration routine begins at a block  600  where the user is instructed to answer yes or no to six preliminary questions, as illustrated on the display screen  700  of  FIG. 8 . The six questions are shown in a first column which includes the following: 
     1. Setup panels 
     2. Setup breakers 
     3. Setup inputs 
     4. Setup zones 
     5. Setup I/O mappings 
     6. Setup schedules 
     For each option, the user can select Yes or No at a display location  704 . Once the user has answered all of the questions, then the user presses an arrow  706  for the configuration routine to continue. 
     Referring again to  FIG. 7 , a decision block  602  determines if the answer to question 1, Setup Panels, is Yes. In one embodiment of the invention the user may be required to select yes to the Setup Panels option. The user will access the Setup Panels option during initial configuration or to make changes. If the user selects yes, then a panel setup screen for a first panel is displayed at a block  604 . The panel setup screen enables the user to indicate for each of up to eight panels whether or not a panel is present and provide identifying information for the panels. This continues until the user has accessed the last panel setup screen at a block  606 . Thereafter, or if the answer to question 1 was No, then a decision block  608  determines if the answer to question 2, Setup Breakers, was Yes. If so, then the routine continues to a block  610  which shows a breaker setup screen. A breaker setup screen would be shown for each panel that has been previously set up. For example, if only two panels have been set up, then only breaker screens for the two panels will be shown. The user can then identify the locations in each panel of a circuit breaker  108  and/or a remote operated device  110 . This process continues until the user has accessed the last breaker setup screen at a block  612 . 
     Thereafter, or if the answer to question 2 is No, then the configuration routine will continue similarly for the remaining options 3, 4 and 5. For example, the user can set up the thirty-two digital inputs and two analog inputs for each previously identified panel, if the user has chosen the Setup Inputs option. Next, if the user has requested the Setup Zones option, then the user will be provided with a series of screens allowing the user to identify zones each including a plurality of the remote operated devices. For example, it may be desirable to use zone control to control multiple remote operated devices  110  simultaneously. By setting up the zone, the user need only define a particular schedule requirement for a zone, or identify an input device associated with a particular zone. Next, the user can set up I/O mappings by identifying what inputs should be associated with which outputs, i.e., specific individual remote operated devices  110 , or zones of remote operated devices. 
     Finally, a decision block  614  determines if the answer to question 6, Setup Schedules, is Yes. If so, then a block  616  displays a first schedule set up screen enabling a user to configure a schedule for each remote operated device and/or zone, or the like. In accordance with the invention, the schedule guides the user so that it is only necessary to provide scheduling for panels which have been previously been configured and breaker locations which have previously been configured. This continues until the last scheduled set up screen has been completed at a block  618 . Thereafter, or if the answer to question 6 was No, then the wizard is completed at a block  620 . 
     Thus, in accordance with the invention, the set up wizard dynamically creates only the required display screens to display to the user in a step by step setup process. 
     The present invention has been described with respect to flowcharts and block diagrams. It will be understood that each block of the flowchart and block diagrams can be implemented by computer program instructions. These program instructions may be provided to a processor to produce a machine, such that the instructions which execute on the processor create means for implementing the functions specified in the blocks. The computer program instructions may be executed by a processor to cause a series of operational steps to be performed by the processor to produce a computer implemented process such that the instructions which execute on the processor provide steps for implementing the functions specified in the blocks. Accordingly, the illustrations support combinations of means for performing a specified function and combinations of steps for performing the specified functions. It will also be understood that each block and combination of blocks can be implemented by special purpose hardware-based systems which perform the specified functions or steps, or combinations of special purpose hardware and computer instructions.