Control algorithm of variable speed pumping system

• US 8,019,479 B2
• Filed: 11/23/2005
• Issued: 09/13/2011
• Est. Priority Date: 08/26/2004
• Status: Active Grant

• Current Assignee: Danfoss Low Power Drives, Pentair Water Pool And Spa Incorporated (Pentair Plc (Ireland))
• Original Assignee: Pentair Water Pool And Spa Incorporated (Pentair Plc (Ireland))
• Inventors: Lungeanu, Florin, Berthelsen, Lars Hoffmann, Yahnker, Christopher R., Harvest, Nils-Ole, Cox, Everett, Stiles, Robert W., Hansen, Arne Fink, Steen, Donald, Woodcock, Walter J. Jr., Murphy, Kevin, Kjaer, Gert, Westermann-Rasmussen, Peter, Hruby, Daniel J., Morando, Alberto, Robol, Ronald B., Runarsson, Einar Kjartan
• Primary Examiner(s): Decady; Albert
• Assistant Examiner(s): Lee; Douglas S
• Application Number:
  US11/286,888
• Publication Number:
  US 20070114162A1
• Time in Patent Office: 2,120 Days
• Field of Search: 700/282, 417/42, 417/43, 417/44.1, 417/53, 134/6, 210/739, 340/825.69
• US Class Current: 700/282
• CPC Class Codes: F04B 49/065 and making use of computers
• 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 9/004 Priming of not self-priming pumps

Abstract

A pumping system includes a pump for moving water. In one aspect, this is in connection with performance of an operation. The system includes a variable speed motor operatively connected to drive the pump. A value indicative of flow rate of water is determined and the motor is controlled to adjust the flow rate indicative value toward a constant. A value indicative of flow pressure is determined and the motor is controlled to adjust the flow pressure indicative value toward a constant. A selection is made between flow rate control and flow pressure control. In another aspect, the pump is controlled to perform a first operation, and is operated to perform a second water operation. Control of operation of the pump to perform the first water operation is altered in response to operation of the pump to perform the second operation.

Claims

1. A pumping system for at least one aquatic application, the pumping system comprising:

a pump;

a motor coupled to the pump;

a filter coupled to the pump; and

a controller in communication with the motor, the controller making a sensorless determination of a current value of at least one of pressure and flow rate based only on an input power to the motor, the controller using feedback to maintain the flow rate at a substantially constant value despite an increasing impediment caused by debris accumulating in the filter.

2. The pumping system of claim 1, wherein the controller uses feedback to maintain the flow rate at the substantially constant value by increasing the pressure until the pressure reaches a maximum filter pressure.

3. The pumping system of claim 2, wherein the controller uses feedback to maintain the pressure at a substantially constant value with a decreased flow rate after the pressure reaches the maximum filter pressure.

4. The pumping system of claim 1, wherein the pressure is used to calculate a percentage of filter status.

5. The pumping system of claim 4, wherein the controller generates a filter alarm and stops the pumping system when the percentage of filter status is about 100 percent.

6. The pumping system of claim 4, wherein a backwash cycle is performed to reset the filter status.

7. The pumping system of claim 1, wherein the controller obtains the input power from a hardware input in the form of at least one of a voltage and a current.

8. A pumping system for at least one aquatic application receiving inputs from a user, the pumping system comprising:

a pump;

a motor coupled to the pump;

a filter coupled to the pump; and

a controller in communication with the motor, the controller obtaining from a filter menu a total size of the at least one aquatic application as input by the user and a scheduled time including start and stop times for at least one cycle as input by the user, the controller calculating a filter flow value by dividing the total size by the scheduled time in order to self-adjust to any total size of the at least one aquatic application.

9. The pumping system of claim 8, wherein the controller obtains from a filter menu at least one of cycles of circulation per day and turnovers per day in order to calculate the filter flow value.

10. The pumping system of claim 8, wherein filter flow value includes different flow rates for different time periods of a day.

11. The pumping system of claim 8, wherein the controller substantially continuously adjusts a speed of the motor to maintain an actual flow rate corresponding to the filter flow value.

12. A pumping system for at least one aquatic application, the pumping system comprising:

a pump;

a motor coupled to the pump; and

a controller in communication with the motor, the controller determining a current flow rate based on an input power to the motor, the controller determining whether the current flow rate is above a priming flow value in order to determine whether the pumping system is primed, the controller indicating a priming alarm if the pumping system is not primed before reaching a maximum priming time allotment.

13. A pumping system for at least one aquatic application, the pumping system comprising:

a pump;

a motor coupled to the pump; and

a controller in communication with the motor, the controller obtaining a hardware input including at least one of input power and motor speed, the controller calculating shaft power based on the hardware input, the controller determining priming status based on the shaft power, the controller indicating a priming dry alarm if the shaft power is at least approaching zero for at least about ten seconds.

14. A pumping system for at least one aquatic application, the pumping system comprising:

a pump;

a filter coupled to the pump;

a motor coupled to the pump; and

a controller in communication with the motor, the controller performing routine filtration cycles, the controller automatically at least one of reducing and eliminating at least one of the routine filtration cycles when other operations provide additional water movement to achieve a desired turnover rate.

15. The pumping system of claim 14, wherein the other operations include at least one of a cleaning operation and a secondary filter operation.

16. The pumping system of claim 14, wherein the routine filtration cycles are controlled in response to performance of the other operations.