Integrated sump pump controller with status notifications

• US 10,711,788 B2
• Filed: 12/16/2016
• Issued: 07/14/2020
• Est. Priority Date: 12/17/2015
• Status: Active Grant

• Current Assignee: Wayne/Scott Fetzer Company (Berkshire Hathaway Incorporated)
• Original Assignee: Wayne/Scott Fetzer Company (Berkshire Hathaway Incorporated)
• Inventors: Mayleben, Philip Anthony
• Primary Examiner(s): Plakkoottam, Dominick L
• Assistant Examiner(s): Tremarche, Connor J
• Application Number:
  US15/382,328
• Publication Number:
  US 20170175746A1
• Time in Patent Office: 1,306 Days
• Field of Search: 417 4
• CPC Class Codes: F04D 13/068 Battery powered
• CPC Class Codes: F04D 13/086 the pump and drive motor are both submerged
• CPC Class Codes: F04D 13/14 the pumps being all of centrifugal type deviation valves F04D15/0016
• CPC Class Codes: F04D 15/0088 Testing machines
• CPC Class Codes: F04D 15/0218 the condition being a liquid level or a lack of liquid supply

Abstract

A sump pump system having a primary pump, a fluid level sensor, and a primary controller electrically connected to the primary pump for activating the pump when the fluid level sensor indicates a predetermine fluid level has been reached, the primary controller having a primary interface for communicating with a secondary pump. In some forms, the system includes a secondary pump having a secondary controller electrically connected to the secondary pump and having a secondary interface, the primary and secondary interfaces allowing the primary and secondary pump controllers to communicate with one another and allowing at least one of the primary and secondary pump controllers to assume control of both the primary and secondary pump. Related methods are further described herein.

Claims

1. A back-up pump system comprising:

a primary AC pump and a secondary DC pump, the primary AC pump having a primary switch for operating at least one of the pumps, the primary switch being a solid state switch, and the secondary DC pump having a secondary switch for operating at least one of the pumps;

a back-up battery for powering the secondary DC pump when regular power conditions are interrupted;

a primary controller electrically connected to and configured to operate both the primary AC pump and the secondary DC pump;

a secondary controller, discrete from the primary controller, and electrically connected to at least one of the pumps to operate the at least one of the pumps when the primary controller malfunctions or fails; and

a connector for connecting the primary AC pump to the secondary DC pump so that the pumps may be moved or placed together as an assembly,

wherein the connector is a coupling that has a first interface for aligning with a first AC pump outlet and a second interface for aligning with a second DC pump outlet so that the pumps may be connected to one another and moved or placed together as an assembly;

wherein the first interface is connected to the first AC pump outlet via a first fastener and the second interface is connected to the second DC pump outlet via a second fastener; and

wherein the first AC pump outlet and second DC pump outlet each have internal female pipe threading (FPT) and the first fastener and second fastener are threaded sleeves each having male pipe threading (MPT) on one end that mates with the FPT of the first AC pump outlet and second DC pump outlet, the fasteners further each having a flange portion that engages respective portions of the coupling to secure the coupling to the pumps and the pumps to one another.

2. The back-up pump system of claim 1 wherein the solid state primary switch includes a pneumatic pressure transducer that utilizes pressure differentials to determine when one or more of the pumps should be operated.

3. The back-up pump system of claim 2 wherein the primary controller includes a processor programmed to activate the primary AC pump when the pneumatic pressure transducer indicates that a threshold fluid level has been reached.

4. The back-up pump system of claim 3 wherein the processor is programmed to activate the secondary DC pump when the regular power conditions are interrupted and when the threshold fluid level has been reached.

5. The back-up pump system of claim 3 wherein the processor is programmed to activate the secondary DC pump when the primary AC pump is not lowering the fluid level at a sufficient rate or in a sufficient amount of time.

6. The back-up pump system of claim 1 wherein the primary controller includes a processor programmed to perform a battery health check.

7. The back-up pump system of claim 1 further including a battery charging circuit electrically connected to the back-up battery for charging the back-up battery when regular power conditions are present, and having a battery health monitoring circuit for monitoring battery health.

8. The back-up pump system of claim 7 wherein the battery health monitoring circuit includes a display for displaying indicia indicative of the battery health and an alarm for alerting a user to a problem with the back-up battery based on the monitored battery health.

9. The back-up pump system of claim 8 wherein the alarm is at least one of an audible alarm, a visual alarm or an electronic message alarm.

10. The back-up pump system of claim 8 wherein the display is at least one of a light, a digital display, an analog display, or a mechanical indicator.

11. The back-up pump system of claim 1 wherein the primary controller includes a communication device for transmitting notifications about the pump system to a user.

12. The back-up pump system of claim 11 wherein the communication device includes a transceiver for connecting the primary controller to a wireless network to transmit the notification via the network.

13. The back-up pump system of claim 1 wherein the primary AC pump and secondary DC pump are connected to a diverter valve that diverts fluid flowing from one of the pumps toward a discharge pipe that the pump system is connected to and hinders fluid from backflowing or recirculating back into the other pump.

14. The back-up pump system of claim 13 wherein the diverter valve includes first and second inlets, one common outlet and a diverter body positioned between the inlets, the first inlet being in fluid communication with the primary AC pump and the second inlet being in fluid communication with the secondary DC pump, and the diverter body being movable between:

a first position wherein the diverter body blocks the second inlet and allows fluid to flow from the primary AC pump to the common outlet while hindering fluid flow into the second inlet; and

a second position wherein the diverter body blocks the first inlet and allows fluid to flow from the secondary DC pump to the common outlet while hindering fluid flow into the first inlet.

15. The back-up pump system of claim 14 wherein a first fluid passage extending between the primary AC pump and the common outlet includes a curve or bend, and a second fluid passage extending between the secondary DC pump and the common outlet forms a generally linear fluid passage which allows the second fluid passage to provide less fluid resistance than the first fluid passage to allow the secondary DC pump to operate more efficiently since it is powered by the back-up battery and not an AC power supply.

16. The back-up pump system of claim 15 wherein the curve or bend of the first fluid passage is between 45°

-90° and

the second fluid passage is coaxially aligned with the discharge pipe.

17. The back-up pump system of claim 1 wherein the solid state primary switch includes a pneumatic pressure transducer sensor and the coupling defines a structure for connecting at least a portion of the pneumatic pressure transducer sensor to position the at least a portion of the pneumatic pressure transducer in a desired position in relation to the pumps.

18. The back-up pump system of claim 1 wherein the connector is a member that extends from a top or side surface of the primary AC pump to a top or side surface of the secondary DC pump to connect the pumps together.

19. The back-up pump system of claim 18 wherein the member is a handle that interconnect the pumps so that they can be carried or placed as a connected assembly.