Pump controller system and method

• US 20080181787A1
• Filed: 10/31/2007
• Published: 07/31/2008
• Est. Priority Date: 12/08/2003
• Status: Active Grant

• Current Assignee: Pentair Flow Technologies LLC (Pentair Plc (Ireland))
• Original Assignee: Sta-Rite Industries LLC (Pentair Plc (Ireland))
• Inventors: Koehl, Robert M.
• Granted Patent: US 7,612,510 B2
• Time in Patent Office: Days
• US Class Current: 417/42
• CPC Class Codes: F04B 49/06 Control using electricity regulating by means of floats actuating electric switches F04B49/04
• CPC Class Codes: F04B 49/065 and making use of computers
• CPC Class Codes: F04B 49/10 Other safety measures
• CPC Class Codes: F04D 15/0066 by changing the speed, e.g. of the driving engine
• CPC Class Codes: F04D 15/0088 Testing machines
• CPC Class Codes: F04D 15/02 Stopping of pumps, or operating valves, on occurrence of unwanted conditions
• CPC Class Codes: F04D 15/0236 Lack of liquid level being detected by analysing the parameters of the electric drive, e.g. current or power consumption
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G05B 2219/37371 Flow
• CPC Class Codes: G05D 16/202 actuated by an electric motor
• CPC Class Codes: H02H 7/0852 directly responsive to abnormal temperature by using a temperature sensor in a control circuit H02H7/0833
• CPC Class Codes: H02P 29/00 Arrangements for regulating or controlling electric motors, appropriate for both AC and DC motors arrangements for starting electric motors H02P1/00; arrangements for stopping or slowing electric motors H02P3/00; control of motors that can be connected to two or more different electric power supplies H02P4/00; regulating or controlling the speed or torque of two or more electric motors H02P5/00; vector control H02P21/00

Abstract

A method and apparatus for a pump control system. One or more embodiments of the invention include a pump controller that can perform a self-calibrating procedure, can provide precise motor speed control, can provide a limp mode before shutting down the motor when system parameters are exceeded and/or fault conditions occur, can detect fault conditions, and can store fault conditions for later retrieval.

Claims

1. A method of detecting a fault condition in a motor of a pump, the method comprising:

sensing a first line current value;

sensing a speed of the motor;

attempting to operate the motor in a reverse direction if the first line current value is greater than a programmed threshold and if the speed of the motor is less than a motor speed low threshold;

sensing a second line current value while the motor is operating in the reverse direction;

generating a fault condition code and shutting down a drive to the motor if the second line current value is also greater than the programmed threshold; and

operating the motor in the reverse direction for a time period if the second line current value is less than the programmed threshold and attempting to operate the motor in a forward direction after the time period has elapsed.

2. The method of claim 1 and further comprising generating a fault condition code and shutting down a drive to the motor if the second line current value is greater than about 7 amps.

3. The method of claim 1 and further comprising operating the motor in the reverse direction for about 30 seconds.

4. The method of claim 1 and further comprising indicating to a user that a fault condition code has been generated.