Note: Descriptions are shown in the official language in which they were submitted.
lZ19898
Background of the Invention
This invention relates to a system or apparatus for and
to a method of electrically interconnecting a multiplicity of
lighting fixtures (or other electrical appliances) using
three-phase alternating current (AC) power and using five
conductors, that is, one conductor for each phase, a ground
conductor, and a neutral conductor.
In recent years, modern office and other commercial
buildings have become common which utilize a suspended ceiling
having a grid or matrix framework suspended from the overhead
ceiling/floor structure of the building with the grid framework
supporting removable ceiling panels. The grid framework is
typically constructed so that at desired locations, one or more
of the ceiling panels may be omitted and a fluorescent lighting
fixture may be fitted into the framework in place of the ceiling
panels. For example, the grid framework may form two foot (60.9
cm.) squares for receiving the removable ceiling panels. A
typical lighting fixture may be two feet by four feet and the
lighting fixtures may be arranged in the ceiling framework in
rows with one or two ceiling panels between the ends of adjacent
lighting fixtures of the same row and with one or two ceiling
panels between each row of the lighting fixture.
Oftentimes, in a new office building, it i8 conventional
to install the ceiling panels and lighting fixtures before any
interior partitions forming the suites of offices have been
erected. Then, when the building is leased or when the desired
floor plan is chosen, interior partitions are then erected by
securing the partitions to the floor. Oftentimes, the partitions
- 2 -
i lZl9~g8 'J
are not secured to the suspended ceiling. In the past, the
Iighting fixtures were "hardwired~ by electr$cians requiring
considerable skill and labor. For example, the lighting fixtures
for one suite of offices would be connected on one or more
separate control switches and the lighting fixtures for an
adjacent suite of offices would be connected on a separate
control switch. If it became necessary to rewire the lighting
fixtures, because, for example, of a change in floor plan, it
would be necessary for an electrician to rewire the lighting
fixtures.
Recognizing these problems, various plug/in electrical
wiring systems became commercially available. One such system is
shown in U.5. patent 4,001,571 to Martin. While the system shown
in Martin worked well for its intended purpose, this system
utilized single phase AC electrical power and required the
crossing of the two leads so as to switch the connection of the
lamps from one circuit to the other through the use of so-called
converter adapters. This required the use of stacked plug/in
connectors, and in certain instances, up to five such connectors
must be stacked. Thus, a great many electrical parts were
required for utilizing this system and the possibility of poor
electrical connections within the stacked connectors was
increased.
In the inventor's coassigned U.S. patent 4,134,045, many
f the problems with prior electrical interconnect systems were
overcome by employing convenient, interchangeable, rotating
connectors or by employing connector cables in which two leads
were crossed. The electrical interconnect system shown in the
t ~ ~;~19898
above-mentioned U.S. patent 4,134,045 provided a system in which
interchangeable connections were provided for successive fixtures
in one or the other of the circuits formed by three continuous
wire leads. Electrical components constructed in accordance with
the above-noted U.S. patent 4,134,045 are commercially available
from the Day-Brite Lighting Division, Emerson Electric Co.,
Tupelo, Mississippi under the trademark ELECTRO/CONNECT.
In general terms, the wiring system disclosed in the
above-mentioned U.S. patent 4,134,045 and commercially available
under the trademark ELECTRO/CONNECT syqtem~ utilizes four main
components. First, a so-called distribution interface which is
connected to a panel board by conventional conduit and wire. The
distribution interface includes a number of receptacle power
circuits to which prewired receptacle power cables may be plugged
into. The power cables may lead to branches of lighting fixtures
or to wall mounted utility plugs. When it is des~red to
selectively switch groups or branches of the lighting fixtures
independently of others of the lighting fixtures, a so-called
switching cable assembly is plugged into a common receptacle
provided on each of the lighting fixtures. The switching cable
assembly includes a power in receptacle into which an end from
one of the flexible power cables is inserted to bring power to
that lighting fixture. One or both of the "hot" conductors in
the switching cable assembly may be selectively opened and closed
by single pole, single throw (SPST) wall mounted switch. Each of
the lighting fixtures typically includes a fixture adapter which
receives the switched power from the switching cable assembly and
into which a flexible jumper cable can be plugged so that the
~21989~ v
switched power may energize not only the lighting fixture into
which the switching cable assembly is plugged, but also may
control the energization of a series of lighting fixtures
energized by the jumper cable assemblies connected to the fixture
adapter of the one fixture. Further, the switching cable
assembly includes a power-out receptacle which transfers
electrical power through the switching cable assembly in the same
manner in which the power was received. Thus, the power may be
eontinued to other branches within the office suite.
Additionally, between the switching cable assembly and
the next group of lighting fixtures powered by the circuit, it is
necessary to provide either a crossover cable or a so-called
rotating coupler in which the pin positions of the "hot"
conductors in the plug is reversed or crossed. In this manner,
identical switching cable assemblies and remote switches may be
utilized thus greatly simplifying the number of components
required for this system and greatly simplifying the instructions
for installation.
This commercially available ELECTRO/CONNECT plug-in
wiring system has met with considerable commercial success
because it requires only four standardized, basic components
which are prewired and which snaplock together without even the
use of simple handtools. Moreover, these components are
reuseable so that in the event the floor plan for the office is
changed, the same components may be readily unplugged from one
circuit and replugged into another circuit as required.
~ owever, as can be appreciated, the number of lighting
fixtures that can be powered or energized by one main circuit is
~ g8 v
limited to the current draw of the lighting fixtures. For
example, if power is supplied from a panelboard having 20 amp,
120 volt circuit breakers installed therein, only approximately
15 lighting fixtures may be energized by that circuit if each
lighting fixture has four 40 watt fluorescent lamps.
It had been previously recognized that, in commercial
buildings, three phase power is often available. By utilizing
three phase power to energize the lighting fixtures, lt was
recognized that the number of distribution interface panels
required to energize the lighting fixture could be significantly
reduced. ~owever, because of the increased number of conductors
available, the complexity of and the number of components
required for a three phase, five conductor wiring system was
greater than the system illustrated in the above-mentioned U.S.
patent 4,134,045. Thus, there has been a longstanding need for a
five conductor, three phase flexible plug-in wiring system which
is less complex than prior systems.
Brief Description of the Invention
Among the several objects and features of the present
invention may be noted the provision of an electrical
interconnect system and method for multiple lighting fixtures (or
other electrical applications) in which branch circuitq are more
easily grouped at panelboards and in which the loads are better
balanced than with prior art electrical distribution systems;
The provision of such an interconnect system which
optimizes the number of cables thus requiring less materials;
The provision of such an interconnect system which
permits multi-level switching downstream from a first multi-level
switch point;
-- lZ198~8 ~
The provision of such an interconnecting electrical
system in which standardized crossover cables or rotating
couplers of a standard design may be utilized at any point within
a circuit of the present invention;
The provision of such an interconnecting electrical
system which has the capability of handling three separate phases
in branch runs;
The provision of such an electrical interconnect system
having the capability of handling three parallel legs of the same
phase in a fixture branch run, two of which legs can be
multi-level switched at an upstream point and one unswitched leg
for multi-level switching at downstream points;
The provision of such an electrical interconnect system
in which the number of cable types and other components are
minimized thereby to reduce inventory requirements and to reduce
the number of components required in the field for utilization of
the system;
The provision of such an electrical interconnect system
in which the instructions for installation and use are simple
such that workmen may readily utilize the system without the
requirement of specialized training and without tha requirement
of even simple handtools; and
The provision of such an electrical interconnect system
which is simple to use, which i8 quickly installed, which i3
reliable in operation, and which is reuseable.
Briefly stated, an electrical interconnect system for
multiple lighting fixtures is disclosed comprising a source of
three phase alternating current electrical power, and a plurality
lZ:19898 v
of lighting fixtures. A first gwitching cable assembly ~s
provided between the power source and successive ~ighting
fixtures, and a plurality of power cables, each cable having a
first (A), a second (G), a third (B), a fourth (N), and a fifth
(C) lead, with one of the power cables extending from the power
source to the first switching cable assembly. ~hese reference
characters refer to the drawings of the instant specification.)
The first switching cable assembly has internal circuit
connections for connecting a first series of lighting fixtures to
the first (A), second (G), and fourth (N) leads with the fixtures
of the first series of fixtures being energized by a first phase
of the three phase electrical power. A first switch is connected
to the first switching cable assembly for selectively energizing
and de-energizing the first series of lighting fixtures. A
second switching cable assembly is electrically connected to the
first switching cable assembly via the power cables. Means is
provided between the first and second switching cable assemblies
for cross-connecting the leads of the power cable from the first
switching sable assembly to the cross-connecting means with other
leads in the power cable from the cross-connecting means to the
second switching cable assembly such that the first lead (A) from
the first switching cable assembly becomes the fifth lead to the
second switching cable assembly, the third lead (B) from the
first switching cable assembly becomes the first lead to the
second switching cable assembly, and the fifth (C) lead from the
first switching cable assembly becomes the third lead to the
second switching cable assembly. The second switching cable
assembly has internal circuit connections for connecting a second
121g8g~
series of lighting fixtures to the third (B), second (G) and
fourth (C) leads relative to the first switching cable assembly
with the lighting fixtures of the second series of lighting
fixtures being energized by a second phase of the three phase
electrical power. A second switch is connected to the second
switching cable assembly with the first switch being operable to
control energization and de-energization of the first series of
fixtures without interference with the operation of the second
series of lighting fixtures and with the second switch being
operable to control energization and de-energization of the
second series of lighting fixtures without interference with the
operation of the first series of lighting fixtures.
The method of this invention of interconnecting a
plurality of lighting fixtures into one or more series of
successive fixtures with the fixtures being energized by means of
three phase alternating current electrical power utilizes five
lead power cables with each of the series of fixtures being
selectively energizable and de-energizable with respect to and
independently of one ano~her. More specifically, the method
comprises the steps of extending a first power cable having a
first (A), a second (G), a third (B), a fourth (N), and a fifth
(C) lead therein from a source of three phase alternating current
electrical power. The first power lead i8 connected to a first
switching cable assembly. A first circuit is branched from the
first switching cable assembly for energizing a first series of
lighting fixtures with the first series of lighting fixtures
being energized by a first phase of power using the first (A),
second (G), and fourth (N) leads. A remotely operable first
1219898
.. ', ~ 'V
switch is connected to the first switching cable assembly for
selectively controlling energization and de-energization of the
first series of lighting fixtures. The three phase power
continues from the first switching cable assembly to a second
switching cable assembly with the leads exiting the first
Switching cable assembly be~ng in the same order (i.e., A, G, B,
N, C) as the leads entering the first switching cable assembly.
The leads between the first and second switching cable assemblies
are cross connected such that the first lead (A) from the first
switching cable assembly becomes the fifth lead to the second
switching cable assembly, the third lead (B) from the first
switching cable assembly becomes the first lead to the second
switching cable assembly, and such that the fifth lead (C) from
the first switching cable assembly becomes the third lead to the
second switching cable assembly. A second circuit is branched
from the second switching cable assembly for energizing a second
series of fixtures by a second phase of the three phase
electrical power using the third, second, and fourth leads
relative to the first switching cable assembly. A remotely
operable second switch is connected to the second switching cable
assembly for selectively controlling energization and
de-energization of the second series of fixtures~
Other objects and features of this invention will be in
part apparent and in part pointed out hereinafter.
Brief Description of the Drawings
FIG. 1 is a perspective, semi-diagrammatic view of a
typical suspended ceiling in an office building or the like, the
ceiling having a multiplicity of fluorescent lighting fixtures
-- 10 --
,, i 1219898 ~,
installed therein with the lighting fixtures being electrically
connected to a source of three-phase electrical power by the
electrical interconnection system of this invention and with
groups or branches of the lighting fixtures being selectively
energizable by wall switches in accordance with the system and
method of this invention;
FIG. 2 is a semi-diagrammatic/schematic view of a
multiplicity of fluorescent lighting fixtures energized and
selectively controlled by tbe electrical interconnect system and
method of the present invention, with a first group or branch of
lighting fixtures being energized by a first phase of the three
phase electrical power, with a second branch being energized by
the second phase of electrical power, and with a third branch
being energized by the third phase of electrical power;
FIG. 3 is a portion of the electrical interconnect
system illustrated in FIG. 2 showing three branch circuits in
which three phase electrical power is utilized in regular order
such that the first branch circuit is energized by the first
phase of electrical power, such that the second branch circuit is
energized by the second phase of electrical power, and such that
the third branch circuit is energized by the third phase of
electrical power;
FIG. 4 is a circuit generally similar to that shown in
FIG. 3 in which the circuits of the different phases are utilized
in irregular order;
FIG. 5 is a schematic view of a switching cable assembly
(SCA) in which one remotely located single pole single throw
~SPST) wall switch is utilized for single level switching;
1219898 v
FIG. 6 is a schematic view of an switching cable
assembly similar to that shown in FIG. S in which a pair of 5PST
wall switches are utilized for ~ulti-level switching;
FIG. 7 is a schematic view of an switching cable
assembly generally similar to FIGS. 5 and 6 in which a single
pole, double throw (SPDT) wall switch is utilized for three way
switching;
FIG, 8 is a schematic view of an switching cable
assembly generally similar to FIGS. 5-7 in which a pair of SPST
wall switches are utilized for two circuit switching;
FIG. 9 is a schematic view of the internal wiring of a
rotating coupler or cross over of the present invention for three
phase power;
FIG. 10 is a schematic view of a crossover cable of the
present invention;
FIG. 11 is a schematic view of a distribution interface
junction of the present invention;
FIG. 12 i~ a view of a typical lighting cable of the
present invention having plug-in connectors on its ends;
FIG. 13 is an enlarged vlew of a one plug-in connector
of the cable shown in FIG. 12 and of a portion of a lighting
fixture with portions of the connector broken away and
illustrating a portion of an adapter receptacle installed in the
lighting fixture;
FIG. 14 is an end view of the connector taken along line
14--14 of FIG. 13 illustrating the conductor pins of the
connector;
FIG. 15 is a view taken along line 15--lS of FIG. 13,
illustrating the conductor receptacles of the adapter receptacle;
- 12 -
398 ~_
FIG. 16 is a diagrammatic view of the interconnect
system of this invention showing two conductor rotation options;
FIG. 17 is a diagrammatic view of the system and method
of the instant invention which provides an overview of the
salient features of the instant invention: -
FIG. 18 is a perspective view similar to FIG. 1 of
another arrangement of lighting fixtures installed in a suspended
ceiling and with the lighting fixtures in the room in the
foreground being energized by two phase AC power and with the
fixtures in the room in the background being powered by three
phase power, and with the lighting fixtures being supplied with
power via an alternative embodiment of the interconnection system
of this inventiont
FIG. 19 is a schematic view of the fixtures and
interconnection system illustrated in ~IG. 18;
FIG, 20 is a schematic view similar to FIG. 9 of a
rotating coupler or crossover for two circuits;
FIG. 21 is a schematic similar to FIG. 20 of a rotating
coupler or crossover for three circuits;
FIG. 22 is a schematic of a circuit splitter;
FIG. 23 is a schematic of how a multiple ballast
lighting fixture is wired to the interconnection system of the
present invention for single level switching of the lamp (i.e.,
all of the lamps in the fixture are simultaneously energized or
de-energized);
FIG. 24 is a schematic similar to FIG. 23 wherein the
ballasts of the lighting fixture are wired for multi-level
switching of the lamps (i.e., some of the lamps in the fixture
~ ~Z:19898 ~,
may be energized and de-energized independently of the other
lamps) for selectively changing lighting intensities; and
FIG. 25 is a schematic of a number of the components of
the interconnection system of the present invention as they are
installed in a branch run as, for èxample, shown in branch run
BCA of FIG. 3 in which the lighting fixtures are energized by
single phase power.
Corresponding reference characters indicate
corresponding parts throughout the several views of the drawings.
Description of Preferred Embodiments
Referring now to the drawings, and particularly to FIG.
1, the electrical interconnect system of the present invention,
indicated in its entirety by reference character 1, for
electrically interconnecting a multiplicity of fluorescent
lighting fixtures 3 is illustrated with the lighting fixtures
being supported by a suspended ceiling 5. More specifically, the
suspended ceiling includes a ceiling framework 7 having a
grid-like frame adapted to support removable, liftout ceiling
panels 9. For example, ceiling framework 7 may be constructed so
that the ceiling panels S are square panels approximately two
feet by two feet (60.9 x 60.9 cm) and the framework is suspended
from a roof or ceiling framework tnot shown) above the suspended
ceiling by means of hangers or the like (also not shown) in a
manner well known to those skilled in the art. Typically, the
suspended ceiling 5 is separated from the overhead support
ceiling or floor structure by a distance of several inches to
several feet thereby to accommodate the running of electrical
wiring, heating, air conditioning and ventilating ducts,
~2198g~
plumbing, and the like. Generally, the removable ceiling panels
9 may be lifted upwardly clear of framework 7, rotated, and
removed from the framework.
Rooms are defined within the building of walls by
partitions, as generally indicated at 11. Oftentimes, in a
modern office building or the like, partitions 11 may be formed
by metal studs secured to a floor plate which in turn is rigidly
fastened to the floor. The metal s~uds are typically faced with
drywall sheathing, but the partitions are not fastened to the
suspended ceiling 5, even though the ceiling framework may bear
against the top of the partitions. Such construction allows the
building owner or tenants a great deal of flexibility in
arranging floor plans for suites of offices within the building
as the partitions 11 may be positioned at any desired location
within the building. Upon rearranging the floor plan, partitions
11 may be readily removed and replaced with other partitions.
Conventionally, large commercial buildings, such as
office buildings, having suspended ceilings 5 and partitions 11,
as above described, have a plurality of fluorescent lighting
fixtures 3 arranged in parallel rows (or in other arrangements)
within the suspended ceiling. ~ lighting fixture 3 may have a
sheetmetal frame 12 which i8 adapted to fit within one or two of
the spaces of the ceiling framework 7 normally occupied by one or
more removable ceiling panels 9. The bottom face of the lighting
fixture including the luminaire lens (not shown) is generally
flush with the lower surface of the ceiling panels. For example,
lighting fixtures 3 comprising a row of lighting fixtures may be
two feet by four feet (60.9 x 121.8 cm.) and may have one ceiling
~19898
panel 9 between the ends of adjacent lighting fixtures in the
same row and may have two ceiling panels 9 between lighting
fixtures of adjacent rows. It i8 a common construction practice
to install lighting fixtures 3 in suspended ceiling 5 at the time
the building is under construction, prior to the erection of
partitions 11.
Electrical interconnect system 1 of the present
invention comprises a panelboard, as generally indicated at 13,
to which three phase, alternating curren~ (AC) power is supplied
by means of a suitable service line tnot shown). A distribution
interface panel, as generally indicated at 15, is supplied with
three phase electrical power from panelboard 13 by means of a
conduit-protected conductor 16, Oftentimes, distribution
interface panel 15 is mounted on a permanent structure of the
building, such as on a permanent wall or ceiling member, as
opposed to being mounted on a removable partition 11. The
interface panel 15 includes a so-called interface receptacle 17
into which may be plugged one or more lighting cable assemblies,
as generally indicated at 19.
More specifically, as best shown in FIGS. 12 and 13,
each lighting cable assembly 19 includes one "hot" conductor for
each of the three phases of the tbree phase electrical AC power
with these "hot" conductors being indicated at A, B, and C for
the first, second, and third phases of the three phase power,
respectively. Further, the lighting cable assembly includes a
ground conductor G and a neutral conductor N such that the cable
assembly 19 includes five conductors. A male plug 21 is provided
at one end of lighting cable assembly 19 and a female receptacle
- 16 -
898
23 is provided at the other end of the cable assembly and the
conductors A, B, C, G, and N are enclosed within a flex~ble,
armored conduit 24 whlch in turn i8 secured to male plug 21 and
to female receptacle 23.
Referring again to FIG. 1, the female receptacle plug 23
of lighting cabie assembly 19 is shown to be plugged into the
power-in receptacle of a switch cable assembly as indicated
generally by reference character 25. Generally, the construction
of the switch cable assRmbly 25 i8 similar to that shown in the
coassigned Canadian Patent Nu~ber 1,162,266
dated February 14, 1984.
Each lighting fixture 3 is typically provided with a so-called
fixture adapter, as generally indicated at 27 (see FIG. 13), into
which a male plug-end 21 of cable assembly 19 may be plugged or
into which a switched power-out plug of switch cable assembly 25
may be plugged. More specifically, fixture adapter 27 includes a
power-in receptacle 29a and a power-out receptacle 29b. Each of
the receptacles is provided w1th five conductor pins for making
electrical contact with five mating electrical conductors or pins
on a corresponding male plug 21 or female receptacle 23 of a
lighting cable assembly 19 or on the switched power-out
receptacle of switching cable assembly 25. It will be understood
that the ballasts (not shown) for lighting fixture 3 are wired in
parallel to the conductors interconnecting the receptacles 29a,
29b so that the lamps of lighting fixture 3 are energized and so
that power is supplied to the power out receptacle 29a of the
fixture adapter 27~ As best shown in FIG. 2, additlonal power
cable assemblies 19 may be manually snapped into place in outlet
- 17 -
; lZ~98g8 ~
receptacle 29b of fixture adapter 27 and snapped into place into
the power-in receptacle 29b of the next successive lighting
fixture 3 thereby to provide power to the remaining lighting
fixtures downstream from the first switch cable assembly 25.
As heretofore mentioned, switch cable assembly 25
includes a switched power-out receptacle 53 which may be plugged
in to the power-in fixture adapter receptacle 29a and further
includes a power-in receptacle 49 which mates with the
power outlet end 23 of lighting cable assembly 19. ~dditionally,
the switch cable assembly includes a switch tap receptacle 55 and
a straight through power out receptacle 51. The switch tap
receptacle receives a switched tap cable, as indicated at 31,
which may be run to a remotely mounted wall switch 33, as shown
in FIG. 1. This remotely mounted wall switch 33 may be a single
pole, single throw (SPST) switch, as shown in FIG. 5, for single
level switching of the power downstream from the switch power-out
receptacle of switch cable assembly 25, or, as shown in FIG. 6,
the remote wall switch 33 may be two single throw switches, as
indicated at 33A, for multi-level switching of the power
downstream from the switch power-out receptacle of switch cable
assembly 25A.
As shown in FIGS. 7 and 8, other variations of the
switching cable assemblies may be provided. Specifically, in
FIG. 7, a switch cable assembly 25B is shown for a three-way
switching application in which wall switch 33B is a single-pole,
double throw switch. In FIG. 8, two circuit switching is shown
in which switching cable assembly 25C is controlled by a pair of
independent single pole, single throw switches 33C. The wiring
- 18 -
lZ:19898
V
and electrical operation of switch cable assemblies 25-25C and of
wall switches 33-33C will be e~plained in greater detail
hereinafter.
Further referring to ~IG. 2, downstream from the
straight through power out receptacle Sl of switching cable
assembly 25, another power cable assembly 19 is plugged
thereinto. As indicated generally at 35, means is provided
between the first switch cable assembly 25 and another switch
cable assembly for rotating or cross connecting the conductors or
leads of the power cable assembly 19 from the first switching
cable assembly leading into the rotating or cross connecting
means with the leads in another power cable assembly leading from
the cross connecting or rotating means to the second switch cable
assembly such that the first lead A from the first switching
cable assembly becomes the fifth lead to the second switching
cable assembly, such that the third lead B from the first
switching cable assembly becomes the first lead to the second
switching cable assembly, and such that the fifth lead C from the
first switching cable assembly becomes the third lead to the
second switching cable assembly. This rotating of the leads is
illustrated adjacent rotating coupler 43 in FIG. 2.
More specifically, the rotating or cross connecting
means 35 may be a so-called crossover cable as generally
indicated at 37 and as is illustrated in semi-diagrammatic form
in FIG. 10. Cross over cable 37 is shown to have a power-in plug
39 and a power outlet receptacle 41. As illustrated in FIG. 10,
the conductors from the first and fifth conductor pin locations
in the power-in plug 39 are cross connected or rotated with the
-- 19 --
~Z1~8g8
fifth and first conductor pins of the power out plug 41 so as to
facilitate cross connecting of the conductors.
Alternatively, rotating or cross connecting means 35 may
comprise a so-called rotating coupler, as indicated in its
entirety by reference character 43 (see FIG. 2), and as is
illustrated in diagrammatic form in FIG. 9. More specifically,
rotating coupler 43 has a power-in receptacle 45 and a power-out
receptacle 47 and, like cross over cable 37, electrical
conductors within rotating coupler 43 cross connect conductor
pins 1 and 5 of power inlet receptacle 45 with pins 5 and 1 of
power out receptacle 47 thereby to effect a desired cross
connecting or rotation of the power leads carrying the three
phase power so as to permit other lighting fixtures downstream
from the crossover cable 37 or downstream from the rotating
coupler 43 to be energized by a selected phase of the three phase
AC power and further to permit others of the downstream fixtures
to be selectively energized by wall switch 33 in any desired
manner.
Referring now to FIGS. 5-8, a series of switching cable
assemblies of different internal wiring and of different external
wall switch configurations is shown for different applications.
More specifically, in FIG. 5, a single level switcbing cable
assembly, as indicated in itC entirety by reference character 25,
is shown having a power-in receptacle 49, a power-out receptacle
51, a switched power-out receptacle 53 adapted to be received in
the power-in receptacle 29a of fixture adapter 27 in lighting
fixture 3, and a switch tap receptacle 55 for receiving one end
of a switch tap cable 31 leading to a wall switch 33. In FIG. 5,
- 20 -
~Z1~3~398
it will be noted that the wall switch 33 is a single pole, single
throw switch, as indicated at Sl, and it basically makes and
breaks an electrical circuit leading from conductor pins 1 of
power-$n receptacle 49 to power-out receptacle 51 and to
conductor pins 1 and 3 of the switched power-out receptacle 53.
In this manner, one phase of electrical power, for example phase
A, together with ground conductor G and neutral conductor N may
be supplied to the switch power-out receptacle 53 for energizing
a lighting fixture 3 into which the switch power-out receptacle
is plugged and for energizing a branch of successive lighting
fixtures which are energized by jumper cables, as shown in FIG.
1, which are plugged into the power-out receptacle 29b of fixture
adapter 27.
In FIG. 6, an alternative embodiment of a switching
cable assembly is indicated in its entirety by reference
character 25A for multi-level switching. It will be understood
that reference characters followed by the ~A" suffix indicate
corresponding parts having corresponding functions to the
reference characters described above in regard to the switching
cable assembly 25 of FIG. 5. ~owever, it will be noted that the
wall switch 33A includes two independently operable switches, Sl
and S2, for making and breaking a circuit from pin~ 1 of the
power-in receptacle 49A and the power-out receptacle 51A with
pins 1, 3, and 5 of the switching power-out receptacle 53A
thereby to provide multi-level switching of downstream lighting
fixtures 3 in a manner as will be more fully hereinafter
described.
- 21 -
1219B98
-- ~,
In FIG. 7, still another variation of a switching cable
assembly i5 indicated in its entirety by reference character
25B. In switching cable assembly 25B, wall switch 33B is shown
to be a single pole, double throw switch which makes and breaks a
circuit extending from the conductor between pins 1 of power-in
receptacle 49B and power-out receptacle 51B and pins 3 and 5 of
switch power out receptacle s3B. This permits three way
operation of the switch cable assembly via wall switch 33B.
Still another variation of a switching cable assembly is
illustrated in its entirety by reference character 25 C in FIG.
8. Wall switch 33C is shown to comprise two separate,
independently operable single pole, single throw switches for
selectively energizing two circuits or two different phases of
the three phase power fed into power in receptacle 49C. More
specifically, the first circuit i8 controlled by switch at the
lefthand side of wall switch 33C (as it is viewed in F$G. 8)
which makes and breaks a circuit extending between pins 1 of both
power in receptacle 49C and power-out receptacle 51C and pin 1 of
switched power-out receptacle 53C. Still further, another
independently operable SPST switch is provided in wall switch 33C
which selectively makes and breaks circuits between conductor
pins 3 of receptacles 49C and 51C and pin 5 of switch power-out
receptacle 53C. Thus, by independent, selective operation of the
two SPST switches in wall switch 33C, independent operation of
the two circuits or phases fed into switching cable assembly 25C
by means of pins 1 and 3 of power-in receptacle 49C can be
achieved.
- 22 -
1~198g8
In all instances with switching cable assemblies 25,
2SA, 25B, and 25C, it will be noted that the power-in and
power-out receptacles 49 and 51, respectively, have the same
ordering of conductors. In other words, power is transmitted
straight through the switching cable assembly from the power-in
receptacle to the power-out receptacle and the order of the
conductors is not changed.
In FIG. 11, the internal conductors of the distribution
interface panel 15 is illustrated. Specifically, the conduit
service line 16 is shown to bring two independent circuits each
having three phase AC power therein to supply two different
interface power-out receptacles. It will be understood that
lighting cable assemblies 19 may be readily received in either
receptacle 57 or 59 of distribution interface panel 15.
Referring to FIGS. 2-4 and 17, a typical lighting system
for a commercial building utilizing a plurality of lighting
fixtures 3 electrically interconnected to a source of three phase
AC power by the electrical interconnect system and method of this
invention will be described. In FIG. 2, it is seen that three
phase AC power is conducted from distribution interface 15 to a
first multi-level switching connecting assembly 25A by means of a
power cable assembly 19. At the first multi-level switching
cable assembly, a first phase of electrical power (e.g., phase A)
is split off from the incoming power and is conducted downstream
to a first branch circuit BCA via a variety of cables 19
interconnected to fixture adapters 27 carried by lighting
fixtures 3. As will be hereinafter explained, operation of
various groups of lighting fixtures 3 within each branch circuit
- 23 -
lZ1~8
BCA may be controlled by a variety of additional single level
Switching cable assemblies 25 and corresponding wall switches 33
or by other multi-level switching cable assemblies 25A and
corresponding multi-level wall switches 33A. Still referring to
FIG. 2, other power cable assemblies 19 are interconnected to the
power out receptacle slA of the first multi-level switching cable
assembly 25A such that electrical power including the unused
phases (e.g., phases B and C) are conducted downstream to other
branch lighting circuits, a~ indicated at BCB and BCC. These
other branch circuits are similar to branch circuit BCA, as
described above, but are energized by another of the remaining
phases (e.g., either phase B or C).
Portions of the multi-circuit run shown in FIG. 2 are
illustrated in somewhat greater detail in FIGS. 3 and 4. More
specifically, in FIG. 3, the branch circuits utilize the three
phases of electrical power (A, B, and C) in regular order such
that the first branch circuit is energized by the first phase A,
the second branch circuit 8C8 is energized by the second phase B,
and such that the third branch circuit BCB is energized by the
third phase C. ~owever, in FIG. 4, a circuit is illustrated in
which different phases may be utilized in irregular order such
that, for example, the first branch circuit B Q is energized by
the first phase of electrical power (phase A), such that the
second branch circuit BC8 is energized by a second phase of
electrical power (phase B), such that a third branch circuit BCA'
is again energized by the first phase A of electrical power with
a cross-over cable 37 (as lllu~trated in FIG. 10), being provided
between the multi-level switch cable assemblies 25 between branch
- 24 -
lZ198~8
. ', ~ ~
circuits BCB and BCA'. Still further, a third branch circuit BCC
is provided downstream from the branch circuit BCA'.
Referring now to FIG. 17, a lighting circuit, generally
similar to that illustrated in FIG. 2 is shown, but FIG. 17
includes a number of reference letters, as indicated by the
enlarged letters A-S, for serving as reference points on FIG. 17
to aid in the description of the construction and operation of
the electrical interconnect system and method of the present
invention. More specifically, in FIG. 17, reference letter A
denotes a branch run from a lighting panelboard 13 via a
distribution interface panel 15 and via a cable assembly 19. The
outlet end 23 of cable assembly 19 plugs into the power inlet
receptacle 49A of a multi-level switch cable assembly 25A and the
switched power-out receptacle 53A of switching cable assembly 25A
supplies a single phase of power for energizing the fir~t branch
circuit BCA. The power exiting switching cable assembly 25A via
switch power out receptacle 53A is indicated by reference letter
B on FIG, 17. Thus, a number of lighting fixtures 3 may be
selectively connected to the first phase branch circuit BCA by
the switches Sl and S2 contained in the remote wall switch 33A
interconnected to the switch tap receptacle 55A of the first
switch cable assembly 25A for multi-level switching of a lamp
fixtures 3 in branch circuit BCA. It will be understood that two
levels of switching will result if four-lamp fixtures are
utilized while three levels of independent switching will be
available with this arrangement if three-lamp fixtures are
utilized in branch circuit BCA.
-- 25 --
~ Z~898 V
At reference letter C in FIG. 17, it will be understood
that an unswitched leg of the first phase of branch circuit B Q
extends from reference point ~ through the last fixture to a
second downstream switch point, as indicated by reference letter
D. A number of additional lighting fixtures 3 may be connected
to the unswitched leg of the first phase circuit through one wall
switch Sl via a single level switch cable assembly 25 for single
level switching of the lamp fixtures 3 extending on the subbranch
line between reference Points D and G. As previously noted, the
power exiting a switching cable assembly 2s via the power outlet
receptacle 51 is in the same order utilizing the same conductors
as the power fed into the switching cable assembly via its
respective power-in receptacle 49. Thus, the unswitched leg of
the first phase circuit of branch circuit BCA extends through the
first single level switching cable assembly 25, as indicated at
reference character E, and is fed into the power inlet receptacle
49 of a next multi-level switching cable assembly 25A. A second
subbranch circuit of lighting fixtures, this time capable of
multi-level switching, extends from the switched power out
receptacle of this next multi-level switching cable assembly, as
indicated by reference characters F, G, H, and J. Similarly, the
unswitched leg of the first phase of the first branch circuit BCA
extends through additional multi-level switching cable assemblies
to form other subbranch circuits, as indicated at R and L, and
the circuit can oontinue on to still other switching cable
assemblies (not illustrated), as indicated by reference M.
Referring now to the upper righthand corner of FIG. 17,
it will be seen that a continuation of the second and third phase
- 26 -
~Z1~898
circuits exiting the power-out receptacle 51A of the first
multi-level switching cable assembly 2sA continues, as indicated
by reference character N. A second branch circuit, as indicated
at BCB, may be branched off the second multi-level switching
cable assembly 25A, as indicated by reference characters O and P,
such that the second branch circuit i8 energized by the second
phase of electrical power. Still further, the third phase of
electrical power continues through the second multi-level
switching cable assembly 25A to a third multi-level switching
cable assembly with this third phase of electrical power being
generally indicated by reference character Q. Likewise, a third
branch circuit, as indicated at BCC, can be energized by a third
phase of electrical power exiting the third multi-level switching
cable assembly 25A between reference characters R and S.
Referring now to FIG. 16, it will be understood that the
power-in receptacle 49 and the power-out receptacle 51 of any
switching cable assembly 25 may be designed for any ordering of
the conductors relative to the conductor pin 1-5 locations
according to a number of options. Within the broader aspects of
this invention, a variety of different arrangements of ~onductor
pin locations in the switching cable assemblies, power conductor
cables 19, rotating couplers 43, and other key components of tbis
interconnect system may utilize a variety of conductor location
sequences. ~owever, in the broadest sense of the system and
method of this invention, it is preferred that the conductors
coming into the power in receptacle 49 of an switching cable
assembly be in the following order: a first phase "hot"
conductor; a ground conductor; a second phase ~hot" conductor; a
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121~898
neutral conductor; and a third phase "hot" conductor. It will be
understood, however, that the location of the ground and neutral
conductors may be interchanged between the second and fourth pin
positions within the receptacles of the switching cable
assemblies, power cable assemblies, and other components.
Further, it will be understood that within the broader aspects of
this invention, it is not necessary that the first phase power
conductor occupy the first pin position.
More specifically, it has been found that an optimal
arrangement of the "hot" conductors and of the ground and neutral
conductors results in rotation of the conductors for proper
sequencing enabling downstream remote switching and further
enablinq an optimization or minimization of the number of
different components required for utilization of the electrical
interconnect system and method of this invention. This preferred
wiring of the switch power out receptacles 53 of the switching
cable assemblies 25 has been found to be preferable if it follows
either a so-called option "X" or an option ~y~l sequence, as is
illustrated in ~IG. 16.
More specifically, referring to FIG. 16, it will be seen
that the three phase alternating current fed into the power-in
receptacle 49A of switching cable assembly 25A via a power cable
assembly 19 has the first, second, and third phases of the power
designated, respectively, by reference characters A, B, and C,
connected to conductor pins 1, 3, and 5 of receptacle 49A. As
shown, ground conductor G is connected to pin 2 and neutral
conductor N is connected to pin 4, but it will be understood that
the ground and neutral conductors can be interchanged.
- 28 -
lZlg898
In FIG. 16, under option "xn, it is seen that the first
phase A conductor is utilized for energization of a first
subbranch of lighting fixtures and that this first subbranch of
lighting fixtures is rontrolled by switch Sl of wall sw~tch 33A
connected to the switch tap 51A of the first switching cable
assembly 25A. The other two phases A and B are not utilized for
energization of lighting fixtures at this point in the circuit
and thus are indicated as being stored. Downstream from notation
~X-l", a first rotating coupler 43 is provided such that the
first phase A coupled to the first conductor pin is, within the
rotating coupler, rotated 50 it i8 coupled with the fifth
conductor pin. ~ikewise, the unswitched phase B is rotated from
the third conductor pin to the first conductor pin and the third
phase C (which is selectively switched by switch S2) is rotated
from the fifth conductor pin to the third conductor pin. Then,
at position "X-2", the "hot" conductors connected to pin
locations 1 and 5 are stored whereas the conductor connected to
pin 3 is utilized for energization of another subbranch of
lighting fixtures while the "hot" conductors attached to
conductors pins 1 and 5 are stored.
Thence, downstream from position "X-2", another rotating
coupler 43 is provided whlch rotates the pin positions in exactly
the same order as the first rotating coupler at "X-l". In
particular, under the "X" option, it will be noted that pin
position 1, in each rotating coupler 43, is rotated to pin
position 5 and that pin position 3 is rotated to pin position 1
and that pin position 5 is rotated to pin position 3.
- 29 -
~Z19~98
Under the "Y" option, the conductor at the power-in
receptacle of rotating coupler 43 i5 rotated to pin position 3,
the power-in pin position 3 is rotated to the fifth power out
conductor pin location, and the fifth power-in pin position is
rotated to the first power-out conductcr pin position.
Referring now to FIGS. 18-25, a variation of the
electrical interconnection system and method of the present
invention is illustrated. Generally, FIG. 18 is similar to FIG.
1 showing a plurality of lighting fixtures supported in a
suspended ceiling 5. Three phase electrical power is supplied to
a distribution interface panel 15 by means of a suitable conduit
supply line 16. Power is then supplied from distribution
interface panel 15 to the various lighting fixtures by means of
power cables 19 and other components of the electrical
interconnect system 1 as will be hereinafter described in greater
detail.
Referring specifically to FIGS. 18 and 19, the variation
of the electrical interconnect system 1 of the present invention
shown in these drawing figures includes a room shown in the
foreground of FIG. 18 and in the lefthand portion of.FIG. 19
which is supplied with two phase AC electrical power from
distribution interface panel 15 and another room, as shown in the
background of FIG. 13 or on the righthand side of FIG. 19, which
is supplied with three phase AC power from distribution interface
panel 15. Referring first to the portion of the electrical
distribution system supplied with three phase electrical power,
it will be noted that power from the distribution interface panel
is supplied to the lighting fixtures by means of a suitable power
- 30 -
lZ19~398
cable assembly 19 which in turn is supplied to a switching cable
assembly 25D. This switching cable assembly 25D i5 generally
similar to the single level switching cable asse~bly 2S
illustrated in FIG. 5 and heretofore described; However, the
primary difference between the switching cable assembly 2~ and
the switching cable assembly 2sD is that switching cable assembly
25 was intended to be plugged into the power end fixture adapter
receptacle 29a as is best illustrated in FIG. 1. In
contradistinction, the variation of the electrical interconnect
system 1 illustrated in FIGS. 18-25 is that the fixture adapter
receptacles 29a and 29b have been omitted from lighting fixture 3
and in their place, the frame 12 for lighting fixture 3 is
provided with a suitable aperture (not shown) adapted to receive
a spring loaded bayonet-type securement (also not shown) provided
on the bottom of a so-called fixture adapter, as generally
indicated at 107, which may be snapped into place within the
aperture provided in the fixture frame 12. As illustrated in
FIGS. 23 and 24, a plurality (e.g., four) of leads, as indicated
at Ll - L4, extend into the lighting fixture and may be
selectively connected to the ballasts within the lighting
fixtures for either single level control (as shown in FIG. 23) or
for multi-level control (as shown in FIG. 24). More
specifically, single level control is defined such that all of
the lamps controlled by the ballast within these lighting
fixtures are simultaneously energized and de-energized. On the
other hand, multi-level control lndependently wires the inboard
lamp ballast and the outboard lamp ballast so that the inboard
and outboard lamps of the lighting fixture may be independently,
- 31 -
1219l~98 ~,
selectively controlled by means of multiple level swltching as
from wall switches 33A such that the intensity of the lighting
within the room may be varied. Further referring to FIG. 23 and
24, it will be noted that each of the fixture adapters 10`~
includes a power in receptacle 109 and a power out receptacle 111
such that other components, such as an appropriate switch cable
assembly 25D or an appropriate power cable 19, may be plugged
into place within the fixture adapter.
Referring to FIGS. 20 and 21, alternate means 35 for
rotating the orientation of the conductors within the varlous
electrical components is shown to comprise a so-called two
circuit crossover or rotating coupler as generally indicated at
43A and 43B, as is shown in FIG. 20 and 21, respectively. It is
believed, especially in view of the previous descriptions of
rotating connector 43, as heretofore described and as is shown in
FIG. 9, that the construction and operation of the two circuit
rotating connector 43A (FIG. 20) and the three circuit rotating
connector 43B (FIG. 21) will be readily apparent to those skilled
in the art.
Referring now to FIG. 22, a so-called circuit splitter,
as indicated generally at 103, i5 shown. Such a circuit splitter
may be utilized in any circuit, whether the circuit is single
phase, two phase or three phase. Specifically, the circuit
splitter 103 is shown in FIG. 18 in the two phase portion of the
lighting circuit shown so as to receive power from the first
lighting fixture and to split the power in substantially equal
circuits to the remaining lighting fixtures.
- 32 -
- 121~ 8
-- ~,
Referring now to FIG. 25, the various components of the
alternative embodiment of the electrical interconnect system 1 of
the present invention will be described for a branch circuit,
such as BCA, as illustrated in FIGS. 2-4. More specifically,
this branch circuit includes a multi-level, three way switch
cable assembly, as indicated generally by 2sB'. It will be
understood that the ~primed" reference characters indicate parts
having a correspondlng construction and function to similar parts
heretofore described. The power in receptacle 55B' of switching
cable assembly 25B' receives three phase power from electrical
distribution panel 15 and is so constructed so that one phase of
the three phase power (e.g., phase A) can be selectively opened
and closed, and can be selectively switched between the first and
fifth conductor pins of the switched power out receptacle of the
switching cable assembly 25B' by means of a wall mounted selector
switch 33B'.
As further shown in FIG. 25, this single phase switch
power is conducted to a suitable rotating coupler 43C by means of
a power cable 19. Since only single phase power together with
the ground and neutral leads must be conducted through the
rotating coupler 43C, the wiring of the rotating coupler 43C may
be às shown such that power from the first terminal of the switch
power in receptacle is rotated so as to be applied to the third
terminal of the switch power out receptacle of rotating coupler
43C. Then, power from rotating coupler 43C is transmitted to
another switching cable assembly, as indicated generally at 25D,
for so-called four-way control. Switching cable assembly 25D
includes a wall mounted control switch 33D for selectively
- 33 -
lZ198~8
controlling the switch power out of switching cable assembly 25D
to a so-called second three-way control or rotating coupler, as
generally indicated at 43D. It will be seen that this second
three way rotating coupler has leads Ll-~4 connected to
respective leadwire pigtails which may be connected directly to
the ballasts of the lighting fixture 3 in the manner heretofore
described in regard to the fixture adapters 107 illustrated in
FIGS. 23 and 24.
It will be understood that, within the broader aspects
of this invention, the terms first, second, third, fourth, and
fifth leads or conductors, as utilized in the claims, need not
require an ordered relationship between the various conductors
and need not represent or be associated with any specific "hot"
conductor for three phase AC power, but rather are used as
descriptive identifiers for tracing or identifyinq specific
conductors as they are rotated thereby to permit single level and
multi-level switching of branching lighting circuits. It will be
further understood that one or more of the conductors may be
eliminated from any of the electrical components if, for example,
two phone AC power ~s used.
In view of the above, it will be seen that the other
objects of this invention are achieved and other advantageous
results obtained.
As various changes could be made in the above
constructions or methods without departing from the scope of the
invention, it is intended that all matter contained in the above
description or shown in the accompanying drawing shall be
interpreted as illustrative and not in a limiting sense.
- 34 -
