Drain safety and pump control device

• US 7,931,447 B2
• Filed: 11/17/2006
• Issued: 04/26/2011
• Est. Priority Date: 06/29/2006
• Status: Active Grant

• Current Assignee: Hayward Industries, Inc.
• Original Assignee: Hayward Industries, Inc.
• Inventors: Levin, Alan R., Ortiz, Gary
• Primary Examiner(s): Freay; Charles G
• Assistant Examiner(s): COMLEY, ALEXANDER BRYANT
• Application Number:
  US11/601,588
• Publication Number:
  US 20080003114A1
• Time in Patent Office: 1,621 Days
• Field of Search: 417/306, 417/36, 417/18, 417/279, 417/53, 700/282, 700/28
• US Class Current: 417/38
• CPC Class Codes: F04B 49/002 Hydraulic systems to change the pump delivery
• CPC Class Codes: F04B 49/065 and making use of computers

Abstract

A drain protection device and pump controller for pools, spas, fountains and other fluid containment and circulation systems has a vacuum sensor for sensing a level of vacuum present in the suction conduit leading to the pump(s). The vacuum level is monitored by a computer that controls a vent valve that can vent to atmosphere to reduce the vacuum exerted at a drain. In applications with a flooded pump, e.g., above-ground pools, the vent valve may control the discharge of an accumulator that injects fluid pressurized by the return line into the suction conduit to reduce the vacuum therein. The computer also controls the pump(s) present in the circulation system, viz., turns them off to relieve vacuum when a drain is occluded and also runs them at the selected speed based upon a schedule. The vacuum criteria for vacuum reduction may include progressively sensitive values, some of which may be empirically based. Vacuum criteria may be maintained based upon the operational state of the circulation system, e.g., priming, stabilized running or cleaning. Low vacuum limits protect the pump(s) from dry running. A clogged vacuum conduit leading to the vacuum sensor is sensed based upon the presence of vacuum levels that are atypically constant and error processing invoked.

Claims

1. A method for controlling a fluid containment and circulation system having a fluid receptacle with a fluid outlet through which fluid exits the receptacle, a fluid inlet for returning fluid to the receptacle, a pump that moves the fluid from the fluid outlet through a filter to the fluid inlet, a suction conduit providing fluid communication between the fluid outlet and the pump and a return conduit providing fluid communication between the pump and the fluid inlet, a vacuum sensor for sensing a level of vacuum present in the suction conduit and producing a corresponding output, a vent valve having at least two positions, a first position which fluidly connects the suction conduit to matter outside the suction conduit and a second position which isolates the suction conduit from matter outside the suction conduit and a programmed computer, comprising the steps of:

(A) storing at least one vacuum criteria and an operator-determined pump schedule in said computer;

(B) receiving the output of said vacuum sensor in said computer;

(C) comparing the vacuum sensor output to the at least one vacuum criteria;

(D) selectively generating control outputs to said vent valve as determined by the computer to determine the position of said vent valve and to control the operation of the pump, based upon said vacuum sensor output;

(E) periodically checking the time and comparing it to the pump schedule to determine an operator-determined operational state of the pump for that time and controlling the operational state of the pump accordingly, the pump having a plurality of running speeds for passing the fluid through the filter at a plurality of different rates, the operational state of the pump including the speed at which the pump runs, said at least one vacuum criteria having a plurality of values, a first corresponding to a first running speed of the pump and a second corresponding to a second running speed of the pump.

2. The method of claim 1, wherein the at least one vacuum criteria includes a high vacuum limit and wherein said step (D) further comprises:

positioning the vent valve to the first position when the result of comparing the vacuum sensor output to the high vacuum limit indicates that the high vacuum limit has been violated; and

turning the pump OFF when the high vacuum limit has been violated.

3. The method of claim 2, wherein the at least one vacuum criteria includes a low vacuum limit and further comprising the step of turning the pump OFF when the low vacuum limit has been violated.

4. The method of claim 3, wherein said at least one vacuum criteria includes a vacuum range between a relative high limit and a relative low limit, and further comprising the step of calculating the vacuum range relative to an empirically measured vacuum level.

5. The method of claim 4, wherein each of said high vacuum limit, said low vacuum limit and said vacuum range have a plurality of values, corresponding to a plurality of modes of operation of the fluid containment and circulation system.

6. The method of claim 4, wherein the modes of operation of the fluid containment and circulation system include pump priming mode, stabilized mode, and cleaning mode.

7. The method of claim 6, wherein the plurality of values are calculated relative to empirical vacuum levels measured during the operation of the fluid containment and circulation system in the plurality of operational modes.

8. The method of claim 2, if said steps (C) and (D) result in positioning the vent valve in the first position and turning the pump OFF, further comprising the steps of

(F) waiting a predetermined period;

(G) positioning the vent valve to the second position; and

(H) restarting the pump.

9. The method of claim 8, further comprising the steps of automatically repeating steps (F) through (H) a predetermined plurality of times.

10. The method of claim 9, further comprising the steps of shutting the pump OFF for an indeterminate period following said step of repeating the predetermined plurality of times and requiring overt operator input to restart the pump.

11. The method of claim 1, further comprising the step of saving a log of violations of the vacuum criteria in computer readable media.

12. The method of claim 11, further comprising the step of saving a record of operational states and operator inputs in the log.

13. The method of claim 1, wherein said at least one predetermined vacuum criteria includes a rate of change of the vacuum level.

14. The method of claim 1, wherein the fluid containment and circulation system includes an emergency stop switch and further including the steps of monitoring the state of the emergency stop switch and, in the event that the emergency stop switch is pressed, placing the vent valve in the first position and shutting the pump OFF.

15. The method of claim 14, further including the step of activating a sensory alarm when the emergency stop switch is pressed.

17. The method of claim 1, wherein the fluid containment and circulation system includes a booster pump and wherein the operational state of the booster pump is determined by the operator-determined pump schedule.

18. The method of claim 1, wherein the fluid containment and circulation system includes an override switch by which the operator can control the operational state of the pump independently of the operational state indicated by the operator-determined pump schedule to place it ON when it is scheduled to be OFF.

19. The method of claim 1, wherein the fluid level in the fluid receptacle is at a higher elevation than the pump, and further comprising the step of injecting a pressurized fluid through the vent valve when the valve is in the first position.

20. The method of claim 19, wherein the fluid containment and circulation system includes an accumulator for storing fluid under pressure and wherein said step of injecting includes discharging the fluid stored under pressure in the accumulator.

21. The method of claim 20 wherein the fluid containment and circulation system has a fluid connection between the return conduit and the accumulator with a check valve therein and further comprising the steps of passing fluid pressurized by pressure in the return conduit through the check valve into the accumulator and preventing reverse flow through the check valve.

22. The method of claim 1, further including a step of cycling the vent valve from the second position to the first position and back to the second position at least once when the pump is started.

23. The method of claim 22, wherein said step of cycling includes a plurality of transitions between the second and first positions of the vent valve.

24. The method of claim 4, wherein the relative high limit is lower than the high limit and the relative low limit is greater than the low limit.

16. A method for controlling a fluid containment and circulation system having a fluid receptacle with a fluid outlet through which fluid exits the receptacle, a fluid inlet for returning fluid to the receptacle, a pump that moves the fluid from the fluid outlet to the fluid inlet, a suction conduit providing fluid communication between the fluid outlet and the pump and a return conduit providing fluid communication between the pump and the fluid inlet, a vacuum sensor for sensing a level of vacuum present in the suction conduit and producing a corresponding output, a vent valve having at least two positions, a first position which fluidly connects the suction conduit to matter outside the suction conduit and a second position which isolates the suction conduit from matter outside the suction conduit and a programmed computer, comprising the steps of:

(A) storing at least one vacuum criteria in said computer;

(B) receiving the output of said vacuum sensor in said computer;

(C) comparing the vacuum sensor output to the at least one vacuum criteria; and

(D) selectively generating control outputs to said vent valve as determined by the computer to determine the position of said vent valve and to control the operation of the pump, based upon said step (C) of comparing the vacuum sensor output to the at least one vacuum criteria;

(E) periodically varying the vent valve position by generating test control outputs to said vent valve independently of said steps (C) of comparing and (D) of selectively generating; and

(F) monitoring the vacuum level in response to said step (E) of periodically varying to test the operability of the vacuum sensor and the vent valve by verifying that said step (E) of periodically varying results in a change in vacuum sensor output.

28. The method of claim 16, further comprising the steps of (G) periodically varying the operational state of the pump by generating test control outputs to the pump independently of said steps (C) of comparing and (D) of selectively generating;

and (H) monitoring the vacuum level in response to said step (G) of periodically varying to test the operability of the vacuum sensor and the pump by verifying that said step (G) of periodically varying results in a change in vacuum sensor output.

25. A method for controlling a fluid containment and circulation system having a fluid receptacle with a fluid outlet through which fluid exits the receptacle, a fluid inlet for returning fluid to the receptacle, a pump that moves the fluid from the fluid outlet to the fluid inlet, a suction conduit providing fluid communication between the fluid outlet and the pump and a return conduit providing fluid communication between the pump and the fluid inlet, a vacuum sensor for sensing a level of vacuum present in the suction conduit and producing a corresponding output, a vent valve having at least two positions, a first position which fluidly connects the suction conduit to matter outside the suction conduit and a second position which isolates the suction conduit from matter outside the suction conduit and a programmed computer, comprising the steps of:

(A) storing at least one vacuum criteria in said computer;

(B) receiving the output of said vacuum sensor in said computer;

(C) comparing the vacuum sensor output to the at least one vacuum criteria;

(D) selectively generating control outputs to said vent valve as determined by the computer to determine the position of said vent valve and to control the operation of the pump, based upon said vacuum sensor output, wherein the at least one vacuum criteria includes the constancy of the vacuum level; and

(E) positioning the vent valve to the first position when the result of comparing a plurality of vacuum readings taken at different times indicates that the vacuum is constant in an operating mode typified by a varying vacuum level indicating an inoperable vacuum sensor.

26. The method of claim 25, further comprising the step of turning the pump OFF.

27. The method of claim 25, further comprising the step of repositioning the vent valve to the second position and subsequently checking the vacuum level to ascertain that it fluctuates in a normal manner, otherwise terminating pump operation and placing the vent valve in the first position.

29. The method of claim 25, wherein the inoperability of the vacuum sensor is due to an occlusion of a fluid line communicating between the suction conduit and the vacuum sensor.

30. The method of claim 29, wherein said step (E) of positioning the vent valve to the first position removes the occlusion from the fluid line.