Pump controller system and method

• US 7,990,091 B2
• Filed: 10/31/2007
• Issued: 08/02/2011
• 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.
• Primary Examiner(s): DUDA, RINA I
• Application Number:
  US11/981,739
• Publication Number:
  US 20080131291A1
• Time in Patent Office: 1,371 Days
• Field of Search: 318/432, 318/434, 318/400.01
• US Class Current: 318/432
• 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 pump control system for use with a pump in one of a pool system and a spa system, the pump control system comprising:

a controller connected to a motor of the pump;

a switch connected to the controller, the switch being connected to at least one of a guard and a grate in one of the pool system and the spa system,

the switch providing an active run/stop input to the controller when at least one of the guard and the grate are removed, the active run/stop input causing the controller to automatically disable the motor,

the switch providing an inactive run/stop input to the controller when at least one of the guard and the grate are correctly positioned in one of the pool system and the spa system, the inactive run/stop input causing the controller to automatically enable the motor; and

a memory connected to the controller, the controller storing a state of the run/stop input in the memory.

2. The pump control system of claim 1, wherein the controller includes a digital signal processor and a microcontroller that communicates with the digital signal processor, the microcontroller receiving the run/stop input.

3. The pump control system of claim 1, wherein the switch is a first switch, and further comprising a second switch connected to the first switch in a daisy chain configuration, the controller automatically disabling the motor if either the first switch or the second switch provides an active run/stop input.