WO1998041793A2

WO1998041793A2 - High efficiency lighting system

Info

Publication number: WO1998041793A2
Application number: PCT/US1998/005836
Authority: WO
Inventors: William G. Wilheim
Original assignee: Nextek Power Systems, Inc.
Priority date: 1997-03-19
Filing date: 1998-03-19
Publication date: 1998-09-24
Also published as: WO1998041793A3; CN1269282C; EP0919077A4; US20020003379A1; BR9804830A; JP2001504680A; IL127070A0; US6933627B2; ATE421180T1; US20070222298A1; ES2322406T3; AU748683B2; EP0919077B1; DE69840471D1; MY124174A; IL127070A; US20050099138A1; CN1229533A; TW436598B; HK1020809A1

Abstract

A DC power system (1) capable of serving all electrical end-use applications such as maintains normal lighting conditions by lighting fixtures (Lights) requiring DC electrical power as well as other DC compatible loads. A power control (Control Means) and conversion device (DC Rectifier Means) receives AC electrical power from a public utility (AC line) or similar AC source and converts (DC Rectifier) AC power to DC power and delivers low voltage DC electrical power to lighting fixtures (Lights) or any DC compatible end-use. An alternative DC power source (Batt) or sources may be connected to the device (1) and within the device (1) combined with the converted source in service to the load (Lights). A standby rechargeable battery (Batt) serves as an alternative DC source and may be provided to maintain power during line power outages. Optionally, an alternative DC power source such as a photovoltaic DC electrical power source (PV) may be connected to the power control device (1), to provide DC electrical power proportionally to the DC loads. In a further embodiment, a variety of power sources may be connected to the power device such as a gas driven cogenerator unit to supply DC electrical power. This device may also serve in a stand alone application without AC line grid supplies.

Description

HIGH EFFICIENCY LIGHTING SYSTEM

BACKGROUND OF THE INVENTION

The field of the invention is low voltage, direct current (DC) , high efficiency, uninterruptible lighting and DC power systems capable of operating simultaneously with a multiplicity of alternating current (AC) and DC power sources .

Uninterruptible power supplies are known accessories especially when applied to computer equipment to "ride out" brief line power outages so that no data is lost or compromised and in emergency lighting systems where lighting integrity is essential. Many have limited battery storage capability due to ordinary high battery storage volume requirements and high storage battery unit cost. Therefore, operation periods with conventional uninterruptible means may not be maintained for an extended outage. Some special lighting systems are also protected in a similar fashion by an alternating AC power source for critical applications such as operating rooms in hospitals. Such systems, whether using storage batteries or AC auxiliary power sources tend to be complex and relatively expensive, and as a result are limited to only the most valuable applications. With consideration for cost many of these system are also compromised in output performance and durability. In lieu of such considerations, reduced amounts of auxiliary emergency lighting or other power needs are provided for only special applications and are served by packaged "add-on" systems which are only applied and engaged during power outages and not for normal standard lighting needs; these kinds of packages are often used in stairwells and consist of a simple housing enclosing a battery, basic charger, a power sensor means and one or two simple flood lamps of limited light output capacity.

These prior art systems, even if more complex and elaborate in construction, are compromised in performance, due to cost, and do nothing to enhance lighting quality, efficiency, or in other ways enhance the value of the power application except through its limited uninterruptible operation during critical power outages, and would not be considered as equivalent or economical substitutes for conventional lighting or other end-uses.

OBJECTS OF THE INVENTION It is an object of this invention to provide an uninterruptible lighting system and/or end-use power system that can be more versatile and that can be routinely substituted for conventional building or office lighting and other end-uses as if it where intended for conventional end- use needs without compromised end-use performance.

It is another object of this invention to provide high efficiency operation with lower operating cost than conventional incandescent and fluorescent lighting systems. It is yet another object of this invention to provide longer term uninterruptibility (3 hours +) with small storage volumes .

It is an object of this invention to provide optimum battery management for longer stationary battery storage life, lower maintenance, and more economical operation. It is a further object of this invention to provide for compatible and economical connection to alternate energy sources such as solar photovoltaic (PV) panels, fuel cells and other similar DC power supply devices and to manage these sources in relation to serving the output load or loads while maintaining the storage battery within its preferred performance range.

It is another object of this invention to provide a system with enhanced safety through low voltage operation nominally at 26.6 volts for a two lead-acid, 12 volt battery system at room temperature between the power control unit and the lighting fixtures or other DC end-use devices. Other battery systems may also be applied and the output service voltage so adjusted for optimum battery maintenance and life, while serving a suitable DC compatible load. It is yet another object to achieve high power quality through dynamic high power factor correction and similarly achieving low total harmonic AC supply line distortion.

It is an object of this invention to achieve greater overall application value and service quality with low voltage operation while still using standard building wiring and wire sizes while achieving very small voltage drops.

It is still another object of this invention to provide overall building power integrity for lighting and other end- uses that are immune to area and central disruptions such as bombings and confined disasters through a modular independent power in-line device between the AC circuit breaker and the end-use that increases system and subsystem integrity with simple component standardization.

It is yet another object of the invention to provide a universal power interface that accepts a multiplicity of both AC and DC electric power sources simultaneously and directs them to the lighting and/or end-use application in a shared manner.

It is still another object of the invention to provide a universal power interface that accepts a multiplicity of AC or DC electric power sources singularly and without the other in support of the lighting and/or end-use application with conventional end-use expected quality.

It is still further an object of the invention to provide a method and a means to utilize the invention as a power interface where low voltage, DC operation may be utilized in buildings where there is conventional standard high voltage AC wiring and cable sizes.

It remains still an object of the invention to provide a modular structure which allows the power units to be connected in series to satisfy higher DC operating voltages in increments of the individual power unit design voltage. SUMMARY OF THE INVENTION

In keeping with these objects and others which may become apparent, the present invention includes an application of a high efficiency lighting system for maintaining normal lighting levels and conditions by using normal lighting fixtures incorporating a variety of DC electronic ballasts for use with gas discharge lamps requiring DC electrical power as defined by the voltage requirements of this current invention. The system includes a power control means for receiving

AC and/or DC electrical power from a source and delivering the required low voltage DC electrical power to the lighting fixtures or DC compatible end-use. When connected to an AC power source the power control means converts the source of

AC electrical power into a regulated low voltage DC compatible with the long-term "float" voltage requirements of a stationary rechargeable storage battery electrical system.

A battery provides, on a standby basis, the required DC low voltage electrical power to the power control means. The storage battery as in the example of a lead-acid design is connected to the power control means so that the battery may be maintained in a fully charged and "float" condition by the power control means during normal supply of AC electrical power from the grid or similar AC source .

The power control means also serves to deliver the required DC electrical power from the battery to the DC compatible lighting fixtures or compatible end-use during an AC electrical power outage to maintain the DC operating power without interruption.

The power control means can be a plurality of multiple power control means, each connected to its own battery and/or alternative DC power source for maintaining the lighting or end-use power in a building with multiple rooms and area requirements

An optional photovoltaic (PV) source of DC electrical power may be connected to the power control means for proportionally reducing the amount of electrical power taken from said grid or similar AC source. The control means further is capable of directing any excess PV power, not required by the electrical load to an optionally connected storage battery without exceeding it's safe and stable long- term operating requirements. If the power application does not include the battery the control means will similarly and proportionally support the load with the AC source while not exceeding operational limits.

The storage battery provides, on a standby basis, DC low voltage electrical power to the load, in the event that the control means highly regulated DC voltage drops below the battery voltage, as in the case where the AC source interrupts the converted DC supply from the control means.

Otherwise the power control means maintains the battery in a fully charged and standby "float" condition by electrical power from an AC grid source.

In one version of this invention, AC power input is converted by the power control means into the same regulated

DC "float" voltage, without the use of a battery or axially DC source, thus satisfying a low voltage DC lighting. High efficiency gas discharge lighting is thus achieved by optimum voltage control and very high AC to DC conversion efficiencies provided by the power control means, with its switching-mode voltage regulator design, and further by the elimination of similar AC to DC conversion components in the DC ballasts, as in conventional electronic ballasts designs. While switching-mode voltage regulation is preferred, in this invention the invention is not limited by such voltage regulation means. The power control means may also include circuitry to prevent DC current from exceeding a predetermined limit, while still delivering power. The power control means may also include other circuitry to detect a short circuit such that the power control means can interrupt DC power delivery until the short circuit is removed.

This system for maintaining normal power for lighting fixtures requiring DC electrical power, includes the power control means for receiving DC electrical power from a DC source and delivering required DC electrical power to the lighting fixtures, as well as a power control means converting AC electrical power to DC electrical power.

In a further embodiment for remote use, such as a remote facilities without access to conventional AC power, a high efficiency lighting system maintains normal lighting conditions with lighting fixtures requiring DC electrical power. The remote system includes a power control means for receiving DC electrical power from a suitable auxiliary DC power source such as a photovoltaic panel and delivering required low voltage DC electrical power to the remote facility lighting fixtures and/or compatible end-use application, and a storage battery. The power control means also serves to control charging of a battery to a maximum and optimum state-of-charge.

The battery also provides, on a standby basis, the required DC low voltage electrical power to the power control means. It is connected to the power control means while being maintained in a charged condition by the power control means, during availability of the DC power source as in the case of sunshine hours of input of power from the photovoltaic panel.

Moreover, the power control means delivers required DC electrical power from the battery to the lighting fixtures during periods of time when power from the auxiliary DC source or photovoltaic panel is not available, such as when the source must be interrupted for specific reasons as at night and cloud cover times for the PV source. BRIEF DESCRIPTION OF THE DRAWINGS The present invention can best be understood in conjunction with the accompanying drawings, in which:

Figure 1 is a block diagram of basic power system applied to lighting showing the basic input and output power connections; Figure 2 is a physical block diagram of basic power system used as an uninterruptible lighting system with the battery system connected but without an auxiliary DC power input, such as photovoltaic (PV) .

Figure 3 is a wiring layout of a single lighting circuit configuration using a concept called a cluster that avoids excessive low voltage current carrying cable lengths and voltage drops from the low voltage DC power module;

Figure 4 is a wiring layout of a four power module system accommodating a larger lighting area requirement that avoids excessive low voltage operational cable lengths and voltage drops while supported from a single AC high voltage line and circuit breaker;

Figure 5 is a block diagram of lighting system as in Figure 2 but with a PV panel;

Figure 6 is a front view of power control unit with typical power input and output power connections;

Figure 7 is a wiring diagram and specifications for a two lamp low voltage DC gas discharge ballast having compatibility with the power control unit;

Figure 8 is a wiring diagram and specifications for a single lamp low voltage DC gas discharge ballast having compatibility with the power control unit; Figure 9 is a front view of battery containment enclosure;

Figure 10 is a block diagram of a power control unit showing typical power input and output power connections and the internal functions of the power control unit; and, Figure 11 is a block diagram of an alternate energy option lighting system using natural gas cogeneration as an alternative DC power source. DETAILED DESCRIPTION OF THE INVENTION

Figure 1 shows a block diagram of the major components of an uninterruptible lighting system supported by this invention. This system may also be used for other DC compatible loads that are designed to use the output voltage of the power invention. It may be installed anywhere conventional building lighting or other end-use devices are required. Unlike emergency lighting and other emergency power systems, this is a full service, high quality end-use power product. It functions with standard fixtures, lamps and DC compatible devices, without compromise in output performance in the event of an conventional power failure. This permits normal power supporting functions to continue for extended hours using battery storage without disruption of work activity due to loss of lighting and potentially other power needs. The key subsystem that ties the entire system together is the power control unit (PCU) 1 which normally uses standard AC grid power to support the end-use application and keep the optional storage battery 2 in an optimal state of charge. When used to support lighting the lighting fixtures 3 are gas discharge lamps like fluorescent tubes using electronic ballasts which require a low voltage

(nominal 26.6 volts) DC input supplied by line 5 from power control unit 1. Other lamp types may also be used, such as incandescent lamps. During a power outage, the DC line 5 is supplied by battery 2.

Figure 2 shows a physical block diagram showing the AC electric service panel 6 with a standard three wire cable system supplying either voltages of 120 through 277 VAC to

PCU 1. Battery case 7 normally contains two group 24/27 size deep discharge lead-acid storage batteries 8 wired in series and through a 30 amp fuse 9 and cables 10 and 11 to the PCU 1. The wiring to all lighting fixtures and compatible end- uses 3 is at a nominal working voltage of 26.6 volts DC. In the nominal embodiment, each PCU 1 can power ten two tube 48 inch T8 fluorescent fixtures or 20 single tube fixtures 3 or any equivalent electrical DC load of 25 amps of current at or near the design maintenance voltage of the storage battery system used.

Figure 3 shows a wiring layout for a typical office lighting application 15 with walls 16 as supported by a single PCU 1. A closet area 17 conveniently serves to house a relatively small battery volume 2. The AC line 4 leads to PCU 1 which because of its compact size may be advantageously mounted in the ceiling cavity. The DC wiring 5 to the lighting fixtures is also in the ceiling cavity and due to close proximity of the PCU 1 provides a short wiring path to the lighting fixtures 3. This arrangement of low voltage connected lighting loads forms an integral cluster that many be duplicated many times from a single supporting high voltage AC line as shown in Figure 4 while still minimizing load support voltage drops.

The PCU 1 is electronically input compliant to a wide range of continuous AC supply voltages and will accommodate a range of inputs from 110 to 277 VAC in the PCU l. The input power to the PCU 1 is a nominal 725 watts for an AC rms current ranging from 2.6 to 6.6 amps depending on the AC input voltage. The equivalent range of input AC currents will vary depending on the AC input voltage. Because the PCU 1 is highly power factor corrected to .99, a 20 amp circuit breaker and number 12 wire can be expected to support a large number of PCUs and their corresponding lighting capacity achieving a maximum of 3 PCU's from a 120 volt line. Similarly 6 units may be supported from a 277 volt line for a total DC power output of about 4000 watts and an AC input of

4300 watts respectively.

Figure 4 shows a wiring layout of office area 19 with walls 16 serving 8 small offices and four larger ones. This involves the use of four separate uninterruptible lighting systems using four PCU's 1 and four battery modules 2 located in four central closets 17. The four PCU's are supplied from a single 220 VAC circuit breaker in power panel 6 via AC cable 4 as distributed from distribution box 20. Each of the lighting systems supplies 10 two lamp fixtures 3.

There are several different power modes possible with the PCU 1. Figure 5 shows an uninterruptible lighting system that includes AC electric service panel 6, battery case 7 with batteries 8 and fuse 9 connected by cables 10,11 to PCU 1, as well as photovoltaic (PV) panel 25. This mode allows solar energy to be a auxiliary power source to the AC line while maintaining the storage battery case 7 with batteries 8 as a power supplement during AC outages and solar variations. As shown in Figure 6, a front view of PCU 1, it is a simple matter to wire the PV panel to the PCU 1 without complicated AC power conditioners as in convention PV applications. The PV panel is merely connected to two PV input terminals on the PCU 1. This mode permits high reliability lighting using an AC line, battery back-up, and PV as overlaying power sources.

The simplest power operating mode is when the AC is the only input power source with the PCU 1 supporting a low voltage DC lighting system. Such a system with the PCU 1 alone attached to the AC line is a viable high efficiency lighting system with minimum interface power losses that can pay for itself by reducing energy consumption. By simply connecting the battery subsystem to the basic system above, the user achieves the additional power mode satisfying uninterruptible DC power operation in support of lighting.

Still another power mode of operation is achieved by using the PCU 1 without a battery but with AC input and a PV panel.

In this mode the PV contribution is preferentially absorbed by the DC load with the balance supplied by the AC input.

In still another power operating mode where the PCU 1 may be used as a stand alone power system without grid supported central AC generation. Such a system is desirable in an area remote from the AC grid. With such a system, using the PCU 1 attached to a suitable PV panel and a suitable rechargeable storage battery, solar lighting and other DC load needs may be satisfied including an DC to AC 60 HZ power inverter .

The PCU 1 is distinguished by being sufficiently flexible to support a multiplicity of power operating modes while satisfying lighting and other electrical requirements. It can also supply other DC loads such as household appliances, microwave ovens, DC refrigeration and the like. Furthermore, it can also alternately accept external DC power from many varied sources other than photovoltaic (PV) , such as wind generators or a engine powered DC generator.

Figure 6 also shows a front view of PCU 1 with finned heat sink 28 and terminal strip 29.

Figures 7 and 8 show the wiring diagrams and specifications for the two lamp and one lamp DC ballasts respectively.

Figure 9 shows a front view of the battery case 7 with housing 35, hinged lid 36 and latches 37. It is a thermoplastic case rated for sealed type lead-acid batteries. Figure 10 shows a block diagram of the PCU 1. The AC input is rectified by DC Rectifier Means such as a bridge circuit. The Power Factor Correction Means is used to achieve a high power factor and low total harmonic distortion at the AC input. The Control Means and Voltage Regulator means interact through circuits such as pulse width modulation and DC to DC switching power supply topologies to provide the nominal 26.6 volts to the lighting ballasts or other suitable DC loads through the power junction means. Figure 10 also shows the Control Means and Voltage Regulator means may further interact to limit the upper operating current of PCU 1 and further to shut down the DC output of the PCU 1 in the event of a detected short circuit. Such short circuit detection circuitry being continually active and dynamic and thus resetable at any time to normal. Other voltages including programmable voltages are also possible, such as 13.3, 26.6, 39.9 etc. to support higher series connected battery system and control requirements. The Battery Undervoltage Cut-Off disconnects the battery in situations of charge depletion to prevent over discharging that contributes to chemical and physical damage to the storage battery. The PV Voltage Regulator and Suppressor is a power conditioner/controller to suppress voltage transients and also to prevent dangerous over charging of the storage battery from the PV panel.

Figure 11 is an alternate embodiment for a powered lighting system including natural gas cogeneration. AC power 50 is normally converted to DC power by the PCU 1 consisting of the DC power converter 51 and control means 52 or otherwise specified by the operations of PCU 1. However, a cogenerator in the form of a gas fueled DC generator 53 receives natural gas as an primary energy source from a natural gas source 54, and converts it into DC power to support building lighting system 55, such as electronic ballasted fluorescent lighting. This system can provide a flatter and more predictable power demand curve for electric utilities by altering the customers demand using building the lighting system 55, supplemented by the gas energy source thus mitigating peak power from electric utility generating sources. This can result in reduced demand charges.

The cogeneration system can run continuously for lighting load 55, and does not require costly synchronous 60 HZ power inverters to be sent back through the AC power line 50.

DC gas generator 53 directly couples to building lighting system 55 through the auxiliary DC input of the PCU 1 to operate building lighting system 55. Other embodiments may be applied to the present invention without departing from the scope of the invention, as noted in the appended claims.

Claims

I CLAIM :

1. A power system applied to lighting and other end- use applications system for maintaining normal lighting conditions with conventional lighting fixtures and other end- use electrical power applications requiring DC electrical power, said power system comprising: power control means for receiving AC alternating current electrical power of many frequencies from a source and alternatively DC power from a source, and for delivering required regulated low voltage DC electrical power to voltage matched lamp or lamps within said lighting fixtures and/or at least one DC compatible end-use device load; said power control means converting said AC electrical power to DC voltage regulated electrical power; said power control means combining said converted AC to voltage regulated DC with said alternative DC power source in service to said at least one DC compatible load; said power control means altering said converted DC output voltage as a means of controlling power delivered by said alternative DC power source; and, said power control means supporting electrical load or loads with or without an alternative DC power source in service to said at least one DC compatible load.

2. The power system of Claim 1 further comprising said power control means limiting current at said DC output to a defined upper limit prescribed by a maximum power capability of said power control means while still delivering power.

3. The power system of Claim 1 further comprising said power control means interrupting delivered output power upon detection of a short circuit across output terminals of said power control means.

4. The power system of Claim 1 wherein said alternative DC power source is a rechargeable storage battery and in the event of a power failure from said AC source, said storage battery continues to service said at least one DC compatible load, said rechargeable storage battery being optimally charge maintained in a stationary standby mode by said regulated output voltage of said power control means.

5. The power system of Claim 4 wherein said rechargeable storage battery is activated in support of said at least one DC compatible load upon extinguishing of said AC input to said power control means.

6. The power system of Claim 4 wherein said power control means, in absence of a supporting power source, electrically isolates said rechargeable storage battery from said at least one DC compatible load in the event that a battery state-of-charge, as measured by terminal voltage of said battery, falls below a predetermined value.

7. The power system of Claim 4 wherein said power control means interrupts power to said storage battery from any other connected DC power source in the event said storage battery is fully charged.

8. The power system of Claim 1 in wherein said alternative DC power source is an energy converter that converts an energy source into an electrical compatible DC voltage.

9. The power system of Claim 1 wherein said alternative DC power source is a photovoltaic solar panel.

10. The power system of Claim 1 wherein said alternative DC power source is a photovoltaic fuel cell.

11. The power system of Claim 1 wherein said alternative DC power source is a fossil fueled internal combustion mechanical driven DC electric generator.

12. The power system of Claim 1 wherein said alternative DC power source is a fueled DC cogenerator.

13. The power system of Claim 12 wherein said fueled DC cogenerator is a thermal photovoltaic cogenerator.

14. The power system of Claim 12 wherein fueled Dc cogenerator is a fuel cell generator.

15. The power system of Claim 1 wherein said alternative DC power source produces required DC power.

16. The power system of Claim 4 wherein said storage battery is combined in a power combination with an energy converter which said energy converter converts an energy source into an electrical compatible DC voltage.

17. The power system of Claim 16 wherein said power combination delivers power to said load proportionally.

18. The power system of Claim 16 wherein said power combination delivers power to said load proportionally as a power load leveler.

19. The power system of Claim 4 wherein said power control means for receiving AC alternating current from a source is power factor corrected to near unity, with very low total harmonic distortion reflected to said AC source.

20. The power system of Claim 1 wherein said power control means and said alternative DC power source is arranged close and central to a lighting network of multiple DC loads, said multiple DC loads forming a cluster.

21. The power system as in Claim 20 wherein said cluster is a means to minimize low voltage cable lengths and thus power robbing voltage drops.

22. The power system as in Claim 20 wherein said cluster is a means to insure power integrity local to an area being served even if said the central source of power is in any way interrupted.

23. The power system as in Claim 20 wherein said cluster is power supplied from a standard high voltage AC cable of proportional longer length relative to said DC supported cables .

24. The power system as in Claim 20 wherein said cluster uses multiple power control means, each said power control means having its own cluster and is centrally supplied from a single standard high voltage AC cable of proportional longer length relative to said DC supported cables.

25. The power system of Claim 4 wherein said storage battery is combined in a power combination with an energy converter in a packaged container in service to said DC compatible load or loads.

26. The power system of Claim 4 where said storage battery is combined in a power combination with an energy converter operating in service to a DC compatible load or loads without support of central grid supplied AC power supply as in a non-grid, stand-alone supported power system.

27. The power system of Claim 4 wherein said power control means remain as a central power control point in said power network for all alternative power sources external to the central grid source, and further, wherein said power control means further uses a local source of AC generated power.