Controller system for pool and/or spa

• US 6,407,469 B1
• Filed: 11/30/1999
• Issued: 06/18/2002
• Est. Priority Date: 11/30/1999
• Status: Expired due to Term

• Current Assignee: Balboa Water Group Incorporated
• Original Assignee: Balboa Instruments Incorporated (Helios Technologies, Inc.)
• Inventors: Rosenau, Paul, Cline, David J., Otto, Cindy
• Primary Examiner(s): Ballato, Josie
• Assistant Examiner(s): POLK, SHARON A
• Application Number:
  US09/451,561
• Time in Patent Office: 931 Days
• Field of Search: 307/11, 307/147, 307/42, 307/116, 307/38, 307/39, 307/40, 361/1, 361/104, 361/752
• US Class Current: 307/11
• CPC Class Codes: A61H 2201/0173 Means for preventing injuries
• CPC Class Codes: A61H 2201/0176 By stopping operation
• CPC Class Codes: A61H 2201/50 Control means thereof
• CPC Class Codes: A61H 2201/5082 Temperature sensors
• CPC Class Codes: A61H 33/00 Bathing devices for special therapeutic or hygienic purposes A61H35/00 takes precedence; sprays acting on a body or body part not immersed in water A61H9/00; means for washing bed-ridden persons A61G7/0005; for sub aquatic intestinal cleaning A61M9/00; isolation chambers A61M21/0094; electric or magnetic baths, applying ionised fluids A61N1/44 ; heater for bath tubs F24H1/54
• CPC Class Codes: A61H 33/005 Electrical circuits therefor
• CPC Class Codes: A61H 33/0087 Therapeutic baths with agitated or circulated water
• CPC Class Codes: A61H 33/60 Components specifically designed for the therapeutic baths of groups A61H33/00 plumbing E03C1/00
• CPC Class Codes: H05K 1/0263 High current adaptations, e.g. printed high current conductors or using auxiliary non-printed means; Fine and coarse circuit patterns on one circuit board H05K1/0293 takes precedence

Abstract

A control system for a pool and spa. Main line voltage is provided through a single line voltage service and a single ground fault circuit interrupter circuit, facilitating a ground fault test and simplifying installation. The control system controls the pool and spa equipment, with a circuit board assembly including individual fuse protection devices and switching circuits. A test algorithm is included, wherein the control system is disabled from normal operation if the GFCI test fails. The pool operator manually enters a water fill command, and the controller system automatically opens the fill valve for a predetermined time interval, and then automatically closes the valve. An emergency disconnect switch is mounted near the bathing area, connected by low voltage wiring to the controller system cabinet. The controller system senses the emergency switch closure and disconnects line voltage to the line voltage loads. The emergency switch closure also remotely induces a ground fault, tripping the GFCI. A sensing circuit allows the controller system to sense the presence of the emergency switch system, and issues a warning and prevents normal operation of the pool and spa system if not connected. A gas pressure sensor monitors the natural gas line, and the heater is disabled and a warning given under low pressure conditions. Abnormal filter backpressure triggers a warning when the filter needs service. A temperature sensor has parallel sensing elements in a common housing to provide separate sensing circuits.

Claims

1. A pool controller system for distributing line voltage from a line voltage service to one or more line voltage loads and controlling operation of a pool service system, comprising:

a housing;

a controller circuit board assembly mounted within the housing, including a plurality of line voltage output terminals for connection to respective line voltage loads via line voltage wiring connections, a set of circuit board line voltage contact surfaces, a plurality of circuit conductors for providing circuit connections between the contact surfaces and respective ones of the line voltage output terminals, wherein the controller circuit board assembly routes line voltage from the circuit board line voltage contact surfaces to the output terminals;

a terminal connector structure mounted within the housing, said connector structure having a set of line voltage connectors, each line voltage connector including a pressure connector for pressure connection to a corresponding one of a set of line voltage supply conductors and a connector line voltage contact surface for contacting a corresponding board line voltage contact surface;

removable fastening structures for securing the board assembly in position within the housing such that each of the circuit board line voltage contact surfaces is in intimate electrical contact with a corresponding connector line voltage contact surface, and for permitting the board assembly to be removed for repair or replacement without disconnecting the line voltage supply conductors from said pressure connectors.

2. The system of claim 1 further including:

a plurality of sets of line voltage conductors for connections from the circuit board assembly to the respective plurality of line voltage loads; and

at least one line voltage connector structure for removable connection of the plurality of sets of line voltage conductors to corresponding ones of the line voltage output terminals, wherein the sets of line voltage conductors can be readily connected and disconnected from the board assembly by use of the connector structure.

3. The system of claim 1 further comprising a voltage transformer for transforming the line voltage to low voltage levels, and wherein the board assembly includes:

a plurality of low voltage terminals for connection to low voltage wiring running to low voltage devices;

at least one low voltage connector structure for removable connection of said low voltage wiring, wherein the low voltage wiring can be readily connected and disconnected from the board assembly by use of the at least one low voltage connector structure.

4. The system of claim 1 wherein the board assembly further includes a plurality of non-resettable circuit protection devices for providing circuit protection for the line voltage loads.

5. The controller system of claim 4, wherein the circuit protection devices include fuse devices.

6. The controller system of claim 1, wherein the circuit board assembly includes a prefabricated printed wiring board including conductor traces, and the plurality of circuit conductors are defined by a set of said conductor traces.

7. The controller system of claim 1, wherein said line voltage service is a line voltage supply having a neutral conductor, a first phase conductor and a second phase conductor, and the first phase conductor and the second phase conductor are connected to corresponding ones of said set of line voltage connectors.

8. The controller system of claim 1, further comprising:

a voltage transformer mounted within the cabinet housing for transforming line voltage to low voltage; and

wherein the controller circuit board assembly further includes a plurality of low voltage switches for selectively applying low voltage to respective low voltage output wiring connections.

9. The controller system of claim 1, wherein the housing defines a main compartment and a plurality of secondary compartments, the main compartment having routed therein all line voltage wiring entering the cabinet, the secondary compartments being shielded from the main compartment and having routed therein only low voltage wiring carrying low voltage signals.

10. The controller system of claim 9, wherein the main compartment is separated from the plurality of secondary compartments by conductive inner wall structures.

11. The system of claim 1, wherein each of said circuit board line voltage contact surfaces is a planar, electrically conductive surface, and wherein each said connector line voltage contact surface is a planar, electrically conductive surface, and said removable fastening structures secure a respective planar surface of said circuit board line voltage contact surfaces and a respective planar surface of said connector line voltage contact surface together in intimate electrical and physical contact.

12. The system of claim 11, wherein said printed circuit board is a multi-layer structure having a top surface and a bottom surface, and a first set of circuit traces formed on said top surface, a second set of circuit traces formed on said bottom surface and a third set of circuit traces formed in a buried intermediate layer of the printed circuit board, and wherein said plurality of circuit conductors comprise said first, second and third sets of circuit traces.

13. The system of claim 12, wherein said circuit board contact surfaces are formed on said bottom surface of said printed circuit board.

14. The system of claim 13, wherein traces of said third set are electrically connected to respective traces of said first and second sets by conductive vias, and said line voltage output terminals are on said top surface of said printed circuit board.

15. The system of claim 1, wherein said removable fastening structures secure a corresponding circuit board line voltage contact surface in pressure contact with said connector line voltage contact surface.

16. The system of claim 1, wherein said pressure connector includes a threaded device for capturing said corresponding one of the set of line voltage supply conductors by a pressure connection.

17. The system of claim 16, wherein the pressure connector includes a frame having a threaded opening into which the threaded device is advanced to secure the corresponding one of the set of line voltage supply conductors.

18. The system of claim 1, wherein said terminal connector structure includes a terminal block body fabricated of an electrically insulating material and secured to said housing.

19. The system of claim 18, wherein said terminal connector structure is secured to a surface of said housing, and said pressure connector is disposed at a first height relative to said surface, and said connector line voltage contact surface is disposed at a second height relative to said surface, wherein said second height is greater than said first height.

20. A method for installing a pool controller system in a pool service system including one or more line voltage loads, comprising:

providing a pool controller circuit board assembly, the assembly including a plurality of line voltage output terminals for connection to respective line voltage loads via line, voltage wiring connections, a set of circuit board line voltage contact surfaces, a plurality of circuit conductors for providing circuit connections between the contact surfaces and respective ones of the line voltage output terminals, wherein the controller circuit board assembly routes line voltage from the circuit board line voltage contact surfaces to the output terminals;

providing a terminal connector structure, said connector structure having a set of line voltage connectors, each line voltage connector including a pressure connector for pressure connection to a corresponding line voltage service conductor and a connector line voltage contact surface for contacting a board line voltage contact surface;

mounting the terminal connector structure within a housing;

connecting the set of line voltage service conductors to the terminal connector structure with the set of line voltage connectors;

securing the board assembly in position within the housing with removable fastening structures such that each of the circuit board line voltage contact surfaces is in intimate electrical contact with a corresponding connector line voltage contact surfaces.

21. The method of claim 20 further including:

providing a plurality of sets of line voltage conductors for connections from the circuit board assembly to the respective plurality of line voltage loads;

connecting the plurality of sets of line voltage conductors to corresponding ones of the line voltage output terminals by at least one line voltage connector structure, wherein the sets of line voltage conductors can be readily disconnected from the board assembly by use of the connector structure.

22. The method of claim 20 wherein the board assembly includes a plurality of low voltage terminals for connection to low voltage wiring running to low voltage devices, the method further comprising:

connecting the low voltage terminals to the low voltage wiring using at least one low voltage connector structure for removable connection of said low voltage wiring, wherein the low voltage wiring can be readily connected and disconnected from the board assembly by use of the low voltage connector structure.

23. The method of claim 20, wherein the step of connecting the set of line voltage service conductors to the terminal connector structure includes, for each of the set of line voltage connectors;

tightening a threaded device to achieve pressure contact with a respective line voltage service conductor.

24. A pool controller system for distributing line voltage from a line voltage service to one or more line voltage loads and controlling operation of a pool service system, comprising:

a housing, comprising a main compartment and a plurality of secondary compartments;

a controller circuit board assembly mounted within the main compartment of the housing, including an electronic controller, a plurality of line voltage output terminals for connection to respective line voltage loads via line voltage wiring connections, a plurality of low voltage terminals for connection to respective low voltage devices, a set of circuit board line voltage contact surfaces, a plurality of circuit conductors for providing circuit connections between the contact surfaces and respective ones of the line voltage output terminals, wherein the controller circuit board assembly routes line voltage from the circuit board line voltage contact surfaces to the output terminals, and routes low voltage signals between low voltage circuitry on the circuit board, the controller and the low voltage terminals;

a plurality of line voltage supply conductors passed into the main compartment of the housing from a line voltage supply source;

a plurality of sets of line voltage load conductors passed into the main compartment of the housing from said plurality of line voltage loads and connected to the circuit board assembly;

a plurality of sets of low voltage conductors connected to respective low voltage devices, the sets of low voltage connected routed from respective ones of the secondary compartments into the main compartment for connection to the circuit board assembly;

wherein no conductors carrying line voltage are routed into any of the plurality of secondary compartments.

25. The system of claim 24 wherein:

the line voltage supply is a 240 VAC line voltage supply;

at least one of said line voltage loads is a 240 VAC load; and

at least one of the line voltage loads is a 120 VAC load.

26. A pool controller system for distributing line voltage from a line voltage service to one or more line voltage loads and controlling operation of a pool service system, comprising:

a housing;

a controller circuit board assembly mounted within the housing, including a printed circuit board, a plurality of line voltage output terminals defined on said printed circuit board for connection to respective line voltage loads via line voltage wiring connections, a set of circuit board line voltage contact surfaces defined on said printed circuit board, a plurality of circuit conductors integrally formed with said printed circuit board for providing circuit connections between the contact surfaces and respective ones of the line voltage output terminals, wherein said printed circuit board routes line voltage from the circuit board line voltage contact surfaces to the output terminals;

a terminal connector structure mounted within the housing, said connector structure having a set of line voltage connectors, each line voltage connector including a respective pressure connector for pressure connection to a corresponding one of a set of line voltage supply conductors and a respective connector line voltage contact surface for contacting a corresponding board line voltage contact surface;

removable fastening structures for securing the printed circuit board in position relative to said terminal connector structure within the housing such that each of the circuit board line voltage contact surfaces on said printed circuit board is in intimate electrical contact with a corresponding connector line voltage contact surface of the terminal connector structure, and for permitting the board assembly to be removed for repair or replacement without disconnecting the line voltage supply conductors from said pressure connectors.

27. The system of claim 26, wherein each of said circuit board line voltage contact surfaces is a planar, electrically conductive surface, and wherein each said connector line voltage contact surface is a planar, electrically conductive surface, and said removable fastening structures secure a respective planar surface of said circuit board line voltage contact surfaces and a respective planar surface of said connector line voltage contact surface together in intimate electrical and physical contact.

28. The system of claim 26, wherein said pressure connector includes a threaded device for capturing said corresponding one of the set of line voltage supply conductors by a pressure connection.