Control system for bathers with ground continuity and ground fault detection

• US 6,253,121 B1
• Filed: 06/16/1999
• Issued: 06/26/2001
• Est. Priority Date: 09/03/1998
• Status: Expired due to Term

• Current Assignee: Balboa Water Group Incorporated
• Original Assignee: Balboa Instruments Incorporated (Helios Technologies, Inc.)
• Inventors: Cline, David J., Otto, Cindy, Pinkul, Allan
• Primary Examiner(s): Grant, William
• Assistant Examiner(s): CABRERA, ZOILA E
• Application Number:
  US09/335,308
• Time in Patent Office: 741 Days
• Field of Search: 700/300, 700/11, 700/14, 700/15, 700/17, 700/21, 700/22, 340/649, 340/650, 361/42, 361/49, 361/115, 449/3, 454/12
• US Class Current: 700/300
• CPC Class Codes: A61H 2201/0176 By stopping operation
• CPC Class Codes: A61H 33/005 Electrical circuits therefor
• CPC Class Codes: F24H 15/124 Preventing or detecting electric faults, e.g. electric leakage
• CPC Class Codes: F24H 15/20 characterised by control inputs
• CPC Class Codes: F24H 15/215 before heating
• CPC Class Codes: F24H 15/219 after heating
• CPC Class Codes: F24H 15/281 Input from user
• CPC Class Codes: F24H 15/335 Control of pumps, e.g. on-off control control of compressors of heat pumps F24H15/38
• CPC Class Codes: F24H 15/37 of electric heaters
• CPC Class Codes: F24H 15/395 Information to users, e.g. alarms
• CPC Class Codes: F24H 15/407 using electrical switching, e.g. TRIAC
• CPC Class Codes: F24H 15/414 using electronic processing, e.g. computer-based
• CPC Class Codes: F24H 9/2028 Continuous-flow heaters
• CPC Class Codes: H02H 3/335 the main function being self testing of the device
• CPC Class Codes: H02H 5/105 responsive to deterioration or interruption of earth connection for preventing switching-on H02H11/001

Abstract

A control system for bathers with ground continuity and ground fault detection includes an electronic controller which controls operation of electrically powered devices such as an electric heater assembly connected in a water flow path for heating water. A solid state water temperature sensor apparatus provides electrical temperature signals to the controller indicative of water temperature at separated first and second locations on or within the heater housing. A solid state water presence sensor apparatus determines the presence of water within the heater housing, providing electrical water presence signals to the controller indicative of the presence or absence of a body of water within the heater housing. The system includes ground continuity detection, ground current detection and ground fault detection circuits. The ground continuity detector detects continuity of the electrical ground and provides an electrical detector signal to the controller indicative of a ground continuity status. The ground current detector detects a current flow in the electrical ground line and provides a detector signal to the controller indicative of the current flow detection. The ground fault detection circuitry detects a current imbalance in high power conductors, and disconnects high power outputs from the respective spa devices when a current imbalance is detected, without disconnecting power from the controller.

Claims

1. A control system for bathers, comprising:

an enclosure;

a control circuit assembly, said assembly disposed within said enclosure;

an electrically powered circuit attached to the enclosure and including an electrical ground connected to earth ground;

said control circuit assembly further including ground continuity detector apparatus for detecting a condition that said electrical ground is not connected to earth ground and providing an electrical detector signal to said control circuit assembly indicative of said condition when said electrical ground is not connected to earth ground.

2. A system according to claim 1, wherein the electrically powered circuit includes a heater apparatus including a heater housing fabricated of electrically conductive material, the heater apparatus further including an electric heater element, said heater apparatus attached to said enclosure and having a water entrance and a water exit.

3. A system according to claim 1, wherein said ground continuity detector apparatus comprises:

a light source;

a photo sensor for detecting light emitted by said light source and providing the detector signal, wherein the detector signal is indicative of light detected by the photosensor, the control circuit assembly responsive to said detector signal;

said light source connected in series between an electrical power source and said electrical ground such that said light source is energized to emit light if said electrical ground is properly connected to earth ground, and said light source fails to emit light if said electrical ground is not connected to earth ground.

4. A system according to claim 1 wherein said control circuit assembly is adapted to deactivate said electrically powered circuit in the event said detector signal indicates that said electrical ground is disconnected from earth ground.

5. A system according to claim 1 wherein said control circuit assembly is operable to cause a visible or audible signal to the user indicative of a failure of connection of said electrical ground to said earth ground.

6. A system according to claim 1 further comprising apparatus responsive to a system user'"'"'s input to provide user instruction to said control circuit assembly.

7. A system according to claim 1 wherein the control circuit assembly includes a microprocessor.

8. A control system for bathers, comprising:

an enclosure;

a control circuit assembly, said assembly disposed within said enclosure;

a power supply connected to line voltage to energize said control circuit assembly;

an electrically powered apparatus controlled by the control circuit assembly;

at least one electrical conductor connected from the electrically powered apparatus to earth ground;

said control circuit assembly further including a ground continuity detector circuit for detecting continuity of connection of said electrical conductor to ground and providing a detector signal to said control circuit assembly indicative of a ground disconnection fault status wherein the electrical conductor is not connected to earth ground.

9. A system according to claim 8, wherein said control circuit assembly renders said electrically powered apparatus inoperable when the detector signal indicates that the conductor is disconnected from earth ground.

10. A system according to claim 9, wherein said control circuit assembly is powered by the power supply even while the electrically powered apparatus has been rendered inoperative as a result of the detector signal indicating that the conductor is disconnected from earth ground.

11. A system according to claim 9, wherein the control circuit assembly includes a microprocessor.

12. A control system for bathers, comprising:

an enclosure;

a control circuit assembly, said assembly disposed within said enclosure;

a power supply connected to AC line voltage to energize said control circuit assembly;

an electrically powered circuit connected to AC line voltage, said circuit under control of said control circuit assembly and including an electrical ground connected to earth ground;

said control circuit assembly further including a ground current detector apparatus for detecting flow of current through said conductor to ground and providing a detector signal to said control circuit assembly indicative of a current flow status.

13. A system according to claim 12 wherein said control circuit assembly renders said electrically powered circuit inoperative when the ground current detector apparatus detects current flowing in said ground conductor.

14. A system according to claim 12 wherein said control system includes one or more high power outputs, and wherein said control circuit assembly disconnects said one or more high power outputs from line voltage when the ground current detector apparatus detects current flowing in the ground conductor.

15. A heating and control system for bathers, comprising:

an enclosure;

a control circuit assembly, said assembly disposed within said enclosure;

apparatus to provide user instruction to said control circuit assembly;

heater apparatus including a heater housing fabricated of electrically conductive material, the heater apparatus further including an electric heater element, said heater housing having a water entrance and a water exit, the heater apparatus further including an electrical ground line connected to earth ground; and

ground current detector apparatus for detecting a current flow in said electrical ground line and providing a detector signal to the control circuit assembly indicative of the current flow detection.

16. A system according to claim 15, wherein said ground current detector apparatus comprises a torroid positioned around said ground line, and circuitry to detect an output from said torroid when current flows in said ground line.

17. A system according to claim 15 wherein said current detector apparatus comprises a torroid surrounding said ground line, and a full wave bridge rectifier circuit electronically connected to said torroid, such that current flow will produce an electrical output at said rectifier circuit to condition said output, said electrical output electrically connected to said control circuit assembly.

18. A system according to claim 15 wherein the control circuit assembly is responsive to the detector signal to generate a disconnect signal to disconnect electrical power from the heater element.

19. A system according to claim 15, further comprising:

a power source for providing electrical power;

a switching system for selectively connecting electrical power from the power source to the heater element; and

wherein the switching system is under control of the control circuit assembly, and wherein the control circuit assembly is adapted to actuate the switching system to disconnect electrical power from the heater element in response to said detector signal.

20. A system according to claim 15, wherein the heater housing is attached to the enclosure.

21. A system according to claim 15 wherein said ground current detector apparatus is disposed within said enclosure.

22. A system according to claim 15, wherein the control circuit assembly includes a microprocessor.

23. A control system for a water spa, comprising:

a control circuit located in the vicinity of the spa;

a high power supply connected to said control circuit, the high power supply including at least two power supply conductors;

a control panel connected to the control circuit;

a plurality of high power outputs for connection to one or more spa devices powered by the high power supply;

sense circuitry for detecting a current imbalance in said high power conductors;

disconnection circuit apparatus responsive to said sense circuitry for disconnection of said high power outputs from the respective spa devices when a current imbalance is detected, said disconnection of said high power outputs occurring without disconnecting power from said control circuit;

a test circuit under control of said control circuit to simulate a fault condition to test said sense circuitry and said disconnection circuit apparatus; and

wherein the control circuit is adapted to automatically reset said disconnection circuit apparatus immediately following said test if said sense circuitry operates properly, and is adapted to automatically actuate said test circuit on a programmed schedule without user intervention.

24. A system according to claim 23 wherein said sense circuitry is connected to said control circuit.

25. A system according to claim 23 wherein a current imbalance condition message is displayed on said control panel via characters or numerals in response to commands from the control circuit.

26. A system according to claim 23, wherein said test circuit under control of said control circuit is adapted to create a current imbalance to test said sense circuitry.

27. A system according to claim 26, wherein the control circuit is adapted to periodically actuate the test circuit to test the sense circuitry.

28. A system according to claim 23 wherein said control circuit is responsive to a user command initiated by a user via a control panel input to actuate the test circuit.

29. A system according to claim 23, wherein said disconnection of high power outputs is resettable by a user via a control panel input.

30. A system according to claim 23, wherein:

the control circuit further includes a transformer apparatus connected to the high power supply to transform a high voltage to a low voltage level to provide low voltage power to said control circuit;

said disconnection circuitry is operable to disconnect said high power outputs without disconnecting said high power supply from said transformer; and

said control circuit remains in a powered condition during said disconnection of said high power outputs.

31. A system according to claim 23, wherein said sense circuitry provides a sense electrical signal indicative of a current imbalance condition, and said disconnection circuit includes a relay system and a relay driver system, and wherein said relay driver system is responsive to said sense electrical signal to actuate the relay system to disconnect said high power outputs.

32. A system according to claim 31, wherein the control circuit includes a microprocessor, and said disconnection circuit apparatus operates independently of said microprocessor to disconnect said high power outputs when a current imbalance is detected.

33. A system according to claim 23, wherein the control circuit includes a microprocessor.

34. A system according to claim 23, wherein said test circuit includes a resistor circuit.

35. A system according to claim 34, wherein said test circuit includes a switch circuit under control of said control circuit for selectively connecting the resistor circuit between said at least two power supply conductors.

36. A control system for bathers, comprising:

a control circuit assembly;

a power supply connected to line voltage to energize the control circuit assembly;

at least one conductor connected to earth ground from said control circuit assembly or an electrically powered device under control of said control circuit assembly;

said control circuit assembly further including a ground continuity detector apparatus for detecting a condition that said conductor is not connected to earth ground and providing a ground continuity detector signal to said control circuit assembly indicative of said condition when said electrical ground is not connected to earth ground, and a ground current detector for detecting current flow in said conductor and providing a ground current detector signal to said control circuit assembly.

37. A system according to claim 36, further including:

a plurality of high power outputs;

a plurality of conductors connected between said high power outputs and line voltage;

current imbalance detector circuitry coupled to the plurality of conductors for detecting imbalance in current flow through said plurality of conductors connected to line voltage;

disconnection circuitry responsive to the current imbalance detector circuitry for disconnection of said high power outputs from line voltage when a current imbalance is detected, said disconnection of said high power outputs occurring without disconnecting power from said control circuit assembly.

38. A system according to claim 36, further including:

circuitry responsive to the ground current detector signal for disconnecting the high power outputs in the event current is detected by the ground current detector.

39. A system according to claim 36 further including apparatus responsive to the ground continuity detector signal for disabling operation of the high power outputs when the ground conductor is disconnected, and for providing an error message to the system user indicating ground failure.