Pump controller system and method

• US 7,821,215 B2
• Filed: 11/02/2009
• Issued: 10/26/2010
• Est. Priority Date: 12/08/2003
• Status: Expired due to Term

• Current Assignee: Pentair Flow Technologies LLC (Pentair Plc (Ireland))
• Original Assignee: Sta-Rite Industries LLC (Pentair Plc (Ireland))
• Inventors: Koehl, Robert M.
• Primary Examiner(s): Ro; Bentsu
• Assistant Examiner(s): Paul; Antony M
• Application Number:
  US12/611,048
• Publication Number:
  US 20100141194A1
• Time in Patent Office: 358 Days
• Field of Search: 318/55, 318/56, 318/144, 318/163, 318/400.12, 318/400.22, 318/266, 318/268, 318/280, 318/434, 318/635, 318/650, 318/714, 318/727, 318/779, 318/825, 417/44.1, 417/237, 417/271, 417/325, 417/326
• US Class Current: 318/430
• 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

Embodiments of the invention provide a method of detecting a fault condition in a motor of a pump. The method includes sensing a first current value and a speed of the motor, attempting a recovery operation if the first current value is greater than a current threshold and if the speed of the motor is less than a motor speed low threshold, and sensing a second current value during the recovery operation and shutting down a drive to the motor if the second current value is also greater than the current threshold. The method also includes performing the recovery operation for a time period if the second current value is less than the current threshold and attempting to operate the motor in a normal mode after the time period has elapsed.

Claims

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

sensing a first current value;

sensing a speed of the motor;

attempting a recovery operation if the first current value is greater than a current threshold and if the speed of the motor is less than a speed threshold;

sensing a second current value during the recovery operation;

shutting down a drive to the motor if the second current value is also greater than the current threshold; and

performing the recovery operation for a time period if the second current value is less than the current threshold and attempting to operate the motor in a normal mode 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 current value is greater than about 7 amps.

3. The method of claim 1 and further comprising performing the recovery operation for about 30 seconds.

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