WO2007010270A1

WO2007010270A1 - Modular outdoor electrical supply and distribution system

Info

Publication number: WO2007010270A1
Application number: PCT/GB2006/002724
Authority: WO
Inventors: Carl Attenborough
Original assignee: Carl Attenborough
Priority date: 2005-07-21
Filing date: 2006-07-20
Publication date: 2007-01-25

Abstract

Modular electrical supply and distribution system for outdoor use comprises a number of interconnectable watertight boxes, mountable on a single support backing panel. One box, preferably included in all installations, contains an RCD. A separate box is a power distribution unit which has one or more power output sockets for supplying electrical power to a range of electrical power devices, such as garden pond pumps and water clarification devices. A third box would be similar but would be a lower power rated lighting distribution unit, again with one or more power output sockets for supplying electrical power to a range of electrical lighting circuits. The circuitry inside the individual boxes is primarily on printed circuit boards which connect a mains power input plug for each box to a mains power output socket. Mains power is thus transferred from one box to the next when an array of such boxes is connected to the single support backing panel. The user has no access to the internal wiring of the individual watertight boxes. All electrical connections are through external water resistant plugs and sockets.

Description

TITLE

Modular Outdoor Electrical Supply and Distribution System

DESCRIPTION Field of the Invention

The invention relates to a modular electrical supply and distribution system for outdoor use, that is suitable for installation by an amateur electrician, which satisfies all current existing statutory requirements for installation certification, and which is safe to use.

Background Art

Current EU regulations stipulate that all permanent electrical supplies of 250 volts or less be installed by a certified electrician, or must immediately after installation receive a certificate of competence for the installation. This regulation applies to electrical supplies for internal and for external use. Some suppliers of electrical distribution boxes for outdoor use, for example in the garden, have circumvented this regulation by establishing an outdoor electrical distribution box which is connected by a flexible electrical cable through the external wall of a dwelling to an electrical plug located within the dwelling. The plug can be plugged into the electrical mains power supply of the building, but that is not a permanent electrical connection, so that certification of the electrical competency of the fixed distribution box outside of the building is not necessary. Such distribution boxes contain electrical terminal strips into which can be screwed the wires leading to permanent garden features such as garden pond pumps and ancillary equipment, and garden lighting systems.

Despite the fact that such distribution boxes avoid the legislation designed to control and govern the installation of permanent wiring inside or outside of a building, they still require a high degree of electrical competency because each electrical garden circuit that is to be connected to the distribution box has to be wired through a waterproof gland or grommet in the side wall of the box, and then screw-connected to the relevant terminal block within the box. Fuses may be provided within the distribution box, but electrical knowledge is required in order to know what size of fuse to incorporate into each of the individual circuits. A much lower rated fuse would be required for a lighting circuit, for example, than for a substantially sized pond pump.

In this specification reference to electrical currents assume a 230 volt supply, as in the United Kingdom. The reader will understand that different current levels will be established for 100 volt supply, and may make appropriate conversions.

It is an object of the invention to provide an electrical supply and distribution system for outdoor use, including garden use, marine use or the temporary supply of outdoor lighting or power circuits to a building site, for example. Such a system is not permanently wired to an electrical supply but can, as with the prior art discussed above, be connected to such a supply through a flexible cable and electrical plug. The concept of the supply and distribution system of the invention is, however, to remove all necessity for electrical competency on the part of the user, so the system can be safely and legally installed by someone who has little or no knowledge of electrics.

The Invention

The invention provides a modular electrical supply and distribution system for outdoor use, as defined in claim 1 herein.

One significant aspect of the invention is that the various elements of the distribution system are broken up into separate watertight boxes which can be purchased separately according to the equipment to be powered, and interconnected on a single support backing panel in order to build up a complete electrical supply and distribution centre which can be used without access to any internal wiring on the part of the user. A first such box, or power pod, would typically contain an RCD for interrupting the electrical supply to the other boxes of the installation when an earth leakage current is detected. The RCD power pod would receive its mains electrical supply through a mains power input plug which could be connected to the RCD power pod by a flexible electrical cable. Preferably, however, the mains power input plug is something that is secured fast to one wall of the power pod, and the electrical supply is brought to the power pod through a power cable that can be plugged into any electrical outlet sock internally or externally of a building, and which terminates in an electrical output socket which can be fitted to the mains power input plug of the power pod. Preferably the mains power input plug and associated socket are electrically rated to the necessary standard of water resistance appropriate for permanent outdoor electrical connections. The current standard, for example, is IP68. Typically if the power supply is taken from a 13 amp mains outlet socket, the connection of the power supply is not considered as a permanent supply, and a user may plug in the power supply without breaking current safety regulations. If a higher power output is required, for example 32 amps, then the RCD power pod must be wired back to a main distribution box of the parent power supply. This is a permanent wiring task, and such an installation would require a certificate of electrical competency. Such a certificate is however required only in respect of the power supply to the RCD power pod box, and the other components of the modular system can be added by the unqualified home user. Preferably a power input in excess of the basic 13 amp supply is wired directly to the interior of the RCD power pod box rather than through an electrical plug integral with the box as described above for the much more typical 13 amp supply.

The same RCD power pod carries a mains power transfer output socket, which is preferably similarly IP68 rated. That can connect directly to an associated mains power input plug of any other of the watertight boxes of the system, either directly or through a linking flexible cable having a plug at one end and a socket at the other. Another module of the system would be a power distribution unit or power pod which is provided with a mains power input plug and power transfer output socket exactly similar to, and aligned with, those described above for the RCD power pod. The power distribution unit, however, incorporates one or more power distribution output sockets for supplying electrical power to a range of electrical power devices for use in the garden. Such power devices could include a garden pond pump and associated water clarification or lighting equipment. The power distribution output sockets are fully wired internally of the module, with that wiring being connected to the printed circuit board which distributes the electrical connections from the mains power input plug. Preferably each power distribution output socket carries the IP68 rating, and the individual circuits of electrical power devices to be powered from the power distribution power pod are connected to IP68 rated electrical plugs which plug into the respective power output sockets. The boxes themselves should be at least IP65 rated.

A third module in the series would be a lighting distribution power pod which as described above in relation to the power distribution unit includes a mains power input plug and a mains power transfer output socket, and internally a printed circuit board for distributing the electrical connections from the mains power input plug to the one or more power distribution output sockets. The power distribution output sockets are intended to supply electrical power to a range of electrical lighting circuits, and can therefore be sized differently to, and therefore incompatible with, the power distribution output sockets of the power distribution power pod. The use of differently sized power distribution output sockets ensures that electrical equipment drawing a relatively high current, such as a large sized pond pump, is not accidentally plugged into the lighting distribution unit instead of the power distribution unit. The power output sockets of the lighting distribution unit are, however, also IP68 compliant. Another power pod that could be provided would be one which carries a single mains electrical outlet socket for a portable power tool. As with the other components and modular system, such a waterproof box would also carry its own mains power input plug for receiving a mains electrical supply from a mains power transfer output socket of an adjacent box when mounted on the support backing panel. It is not necessary, however, for the box carrying the single mains electrical outlet socket to incorporate a mains power transfer output socket for connection to further boxes in the modular system, to be mounted on the same support backing panel. Such a socket box for a portable power tool would in effect provide the last of the modules in the array. The mains electrical outlet socket could be a conventional interior electrical socket that is covered by a hinged waterproof or splash proof lid, or it may be a fully rated waterproof socket suitable for permanent exposure to the elements.

Each of the boxes preferably includes a LED or neon indicator visible through a transparent lid, which illuminates to indicate that the box is receiving a supply of mains power. Further LEDs or neon indicators may be provided, visible through the same transparent lid, to indicate to a user when there is a fault in the associated electrical equipment being powered from that particular module.

The power and lighting distribution units preferably can accept inputs, via iP68 rated plugs and sockets, from remote sensors which are effective to control the outputs from one or more of the output sockets. For example, the power distribution unit when used to supply power to a garden pond pump can have an input from a remote float valve which acts to turn off the pump when the pond water level falls. Or a remote proximity sensor or movement detector can provide power to activate a sounding device or security light to scare away an intruder or predator. Drawinqs

Figure 1 is a plan view of a modular electrical supply and distribution system according to the invention;

Figure 2 is a perspective view of a single box selected from the array shown in Figure 1 ;

Figure 3 is a plan view of a support backing panel for mounting an array of interconnected boxes or power pods of the modular system in an outdoor environment;

Figures 4a and 4b are respectively wiring diagrams illustrating the mains power supply to an assembly of an RCD power pod and a lighting power pod of a system according to the invention;

Figures 5a and 5b are respectively the printed circuit boards used in the power pods of Figures 4a and 4b;

Figures 6a and 6b are respectively the front mouldings which lie in front of the printed circuit boards of the power pods of Figures 4a and 4b, showing the positions of the neon power on indicator and of the resettable switches for restoring an electrical output following fault detection;

Figures 7a and 7b are respectively side elevations of an IP68 rated electrical plug and socket, and Figure 7c is a waterproof insert that can be screwed into the open end of the socket of Figure 7b, to render it waterproof.

Figure 8 is a schematic plan view of the bottom edges of two of the boxes shown in Figure 2, showing their dovetail connection; and

Figure 9 is a schematic section through a support backing panel and associated power pod box, showing the dovetail mounting of the boxes on the backing panel.

Referring first to Figurei , the system as illustrated comprises an array of four power pod boxes, each having a water resistance to IP65 standard. A first box 1 houses a residual current device. A second box 2 is a power distribution unit for supplying three external power circuits. Typically if the electrical supply to box 1 was a thirteen amp mains supply, then each individual power distribution output circuit of box 2 would be rated at three amps. Box 3 is a similar distribution unit to that of box 2, but is a lighting distribution unit supplying three separate lighting circuits each rated at one amp. Box 4 is a waterproof box presenting a conventional UK standard three pin outlet socket, for powering a suitable portable power tool. Each of the boxes or modules 1 to 4 has a hinged waterproof transparent cover 5 which in the case of boxes 1 , 2 and 3 is openable to reset the various power protection circuits within the box or to replace a fuse, whereas the cover 5 on box 4 is openable simply to allow access to the electrical socket.

Each of the four boxes contains a neon indicator or LED 6 which illuminates to confirm that a power supply is being supplied to the box.

An alternative embodiment (not illustrated) would incorporate individual RCDs in boxes 2, 3 and 4 in which case box 1 would be redundant.

Figure 2 shows the power distribution unit box 2 in greater detail. Figure 3 shows in plan view the supporting backing panel 7 on which all four boxes can be mounted. The mounting means is described later.

The individual boxes can be used together in a number of different combinations. Figures 4a and 4b show a combination of the RCD box and one lighting power pod. The entire power output capacity of the system, however, is intended to accommodate one power distribution unit and two lighting distribution units, or one power distribution unit, one lighting distribution unit and one portable power tool power outlet box 4. The array can be used with or without the RCD unit 1 , although its use is greatly recommended.

Figure 4a illustrates the power supply to the RCD. The box incorporates a mains power input plug 10 and a mains power transfer output socket 11. Both are shown along a bottom wall of the box, although it will be appreciated that equally they could be provided along the left and right hand vertical walls of the box 1 , preferably partially recessed so that if adjacent boxes are simply pressed one against the other in the direction of the double headed arrow A between Figures 4a and 4b, electrical power supply is transferred from the RCD box 1 to the adjacent lighting distribution box 3. For such a simple plug-in connection between the two boxes, the dovetail connections shown in Figures 2 and 8 between adjacent boxes, which will be described in greater detail later, will of course not be appropriate.

Power is brought to the RCD box 1 through the IP68 rated electrical mains power input plug 10, by bringing a flexible cable carrying mains power to the box and connecting that power through an IP68 rated electrical socket to the plug 10. In the embodiment illustrated, the electrical power is transferred from the RCD box 1 to the lighting distribution box 3 through a flexible cable 12 which has a plug 13 at one end for connection to the power transfer output socket 11 , and a socket 14 at the other end for connection to an electrical input plug 15 of the box 3. The plug 15 is identical to the plug 10.

By opening the door 5 in the box 1 , the RCD can be reset following an electrical fault which causes it to trip.

The box 3 has an electrical mains power transfer output socket 16 which is identical to the power transfer output socket 11 of the RCD box 1 , but in addition it has three lighting power distribution output sockets 17 (only two illustrated) which are similarly IP68 rated but are preferably sized differently so that they are incompatible with the electrical plug at the end of the flexible cable 12. Beneath the window 5 in box 3 are three separate circuit breakers or fuses, one per output circuit, each having an associated LED or neon bulb which illuminates to indicate an overcurrent fault. In the case of resettable circuit breakers, the illumination may for example be internally of the push button switch which resets the circuit breaker. The printed circuit boards of Figures 5a and 5b are mounted internally of their respective boxes. The printed circuit board of Figure 5a is simply three printed circuit conductors for the live earth and neutral elements of the electrical supply. The printed circuit board of Figure 5b can be either a single sided printed circuit board which requires cross wiring connections to be soldered to the back of the board, or it may be a double sided printed circuit board in which those cross connections are also printed circuit connections. The various plugs and sockets 15, 16 and 17 are hard wired to the respective connections of the printed circuit board.

Figures 6a and 6b show simply the general outline of front plates which are inserted into the boxes in front of the printed circuit boards, to prevent access to the printed circuit boards when the front window is open, and to support the power on indicator 6 and the RCD in the case of box 1 and the power on indicator 6 and the fuses or reset buttons of the lighting box of Figure 3.

The power distribution unit 2 is exactly similar to the lighting distribution unit 3 expect that it is rated differently. Each lighting power distribution circuit from the output sockets 17 is rated at one amp, whereas each power distribution circuit from corresponding outputs of the power distribution unit 2 is rated at three amps.

Figures 7A and 7B illustrate typical 2- or 3-pin plugs and sockets which can be used as the plug 13 and socket 14 described earlier. Figure 7C illustrates a weatherproof filler 19 that can be used with the socket 14, to cover the power connector pins and keep the socket watertight to 1P68 even if it is hanging free and does not receive its plug 13.

It will be appreciated that the individual boxes of the supply system can be mounted with a considerable degree of independent freedom on the mounting support backing panel 7 of Figure 3. Preferably adjacent boxes interlock by means of dovetailed interlocking mouldings as shown in Figures 2 and 8, a dovetail slot 20 or a pair of such dovetail slots being moulded into the vertical wall at one side of each box, and cooperating with a dovetail projection 21 or a pair of such dovetail connections on the facing side of an adjacent box. Once the boxes have been assembled in this way, they are preferably slid laterally onto the mounting plate 7 with a similar engagement between dovetail slots 23 in the bottom of the aligned boxes 1 to 4, engaging with dovetail projections 22 on the mounting plate 7. Instead of a dovetail profile for the slot 20 and projections 21 and 22, any other slide connection profile may of course be adopted.

The benefits of the system of the invention are that no electrical wiring is needed. The entire system simply plugs together. The system is not permanently connected to a mains power supply unless it requires an input power supply in excess of 13 amps, so it does not require a certificate of electrical competence for its installation. Every element is fully compliant or water resistant to IP65 or 1P68, and is also fully wired internally. By the optional additional step of using different sizes of plugs and sockets for the mains power transfer, 10, 11 , 15 and 16, to that of the individual circuit power distribution outputs 17, all risk of wrong connections by the inexperienced user is avoided. Furthermore by making the electrical power distribution outputs 17 to the lighting circuits incompatible with the corresponding electrical power distribution outputs to the power circuits from the box 2, the user will find it impossible to connect a highly rated pond pump, for example, to the lighting distribution unit 3.

Claims

Ciaims

1. A modular electrical supply and distribution system for outdoor use, comprising at least one power distribution unit having one or more power distribution output sockets for supplying electrical power to individual electrical power devices; and at least one lighting distribution unit having one or more power distribution output sockets for supplying electrical power to individual electrical lighting circuits; wherein each power or lighting distribution unit comprises: a waterproof box a mains power input plug fixed to an exterior surface of the box; a mains power transfer output socket fixed to an exterior surface of the box; and a printed circuit board mounted internally of the box for distributing electrical connections between the mains power input plug, the mains power transfer output socket and the power distribution output sockets, which are fixed to an exterior surface of the box; and wherein a RCD (residual current device) is provided for interrupting an electrical supply when an earth leakage current is detected, the RCD being either:

(a) a separate RCD for each of the power or lighting distribution units and being housed in the box with the printed circuit board of that power or lighting distribution unit or

(b) a common RCD for all of the power and lighting distribution units and being housed in a waterproof box for the RCD, with a mains power input plug fixed to an exterior surface of the box and a mains power output socket from the RCD fixed to an exterior surface of the box; and wherein the mains power transfer output socket of each of the watertight boxes is connectable to the mains power input socket of an adjacent box when mounted on a support backing panel.

2. A system according to claim 1 , wherein the individual boxes have openable waterproof lids providing access to internal control switches or fuses associated with the printed circuit boards mounted internally of the boxes..

3. A system according to claim 2, wherein the lids are transparent.

4. A system according to claim 3, wherein each box has a LED or neon indicator visible through the transparent lid for illumination to indicate that the box is receiving a supply of mains power.

5. A system according to claim 3 or claim 4, wherein each box has a LED or neon indicator visible through the transparent lid for illumination to indicate a fault condition in electrical equipment supplied by the box.

6. A system according to any preceding claim, wherein the mains power input plug of each watertight box is a waterproof plug with shrouded male electrical connectors for receiving a female mains power output socket.

7. A system according to claim 6, wherein the mains power transfer output socket of each watertight box is a waterproof socket with female electrical connectors for receiving a male mains power input plug.

8. A system according to claim 7, wherein the mains power input plug connected to one box connects directly to the mains power input socket of an adjacent box when the boxes are mounted on the support backing panel.

9. A system according to claim 7, wherein the mains power transfer output socket of one box is connected to the mains power input plug of an adjacent box when the boxes are mounted on the support backing panel by a flexible cable connection having a waterproof plug at one end for connection to the mains power transfer output socket of the one box and a waterproof socket at the other end for connection to the mains power input plug of the adjacent box.

9.

10. A system according to any preceding claim, wherein each of the power

5 distribution output sockets of the power distribution unit is a waterproof socket for accepting a wired plug of an associated electrical power device such as a garden pond pump.

11. A system according to claim 10, wherein each power distribution output 10 socket of the power distribution unit has an associated fuse or resettable overcurrent protection circuit breaker located within the power distribution unit.

12. A system according to claim 10 or claim 11 , wherein the power distribution unit also comprises one or more signal input plugs or sockets for

15 receiving signals from one or more sensors for disconnecting the power supply sent over the printed circuit board to one or more of the power distribution output sockets in response to a sensed external condition.

13. A system according to any preceding claim, wherein each of the power 20 distribution output sockets of the lighting distribution unit is a waterproof socket for accepting a wired plug of an associated electrical lighting circuit.

14. A system according to claim 13, wherein each power distribution output socket of the lighting distribution unit has an associated fuse or resettable

25 overcurrent protection circuit breaker located within the electrical lighting unit.

15. A system according to claim 13 or claim 14, wherein the electrical lighting unit also comprises one or more signal input plugs or sockets for receiving signals from one or more remote sensors for disconnecting the

30 power supply sent over the printed circuit board to one or more of the power distribution output sockets in response to a sensed external condition.

16. A system according to any preceding claim, comprising a further watertight box connectable to the same support backing panel, carrying a single mains electrical outlet socket for a portable power tool, and a mains power input plug for receiving a mains electrical supply from a mains power transfer output socket of an adjacent box when mounted on the support backing panel.

17. A system according to claim 16, wherein the mains electrical outlet socket for the portable power tool is a conventional interior electrical socket but is coverable by a hinged waterproof or splash proof lid.

18. A system according to claim 16, wherein the mains electrical outlet socket for the portable power too\ is a waterproof socket.

19. A system according to any preceding claim, wherein each box is connectable to its adjacent box or boxes on the support backing panel by dovetail or other sliding key way connections between the adjacent boxes.

20. A system according to any preceding claim, wherein each box is connectable to the support backing panel by dovetail or other sliding keyway connections between the box and the support backing panel.