Low maintenance spa control system

• US 8,112,164 B2
• Filed: 12/12/2008
• Issued: 02/07/2012
• Est. Priority Date: 09/27/2007
• Status: Active Grant

• Current Assignee: Balboa Water Group Incorporated, Balboa Water Group LLC (Helios Technologies, Inc.)
• Original Assignee: Balboa Instruments Incorporated (Helios Technologies, Inc.)
• Inventors: Hollaway, Jerrell P.
• Primary Examiner(s): ROBERTSON, DAVID
• Application Number:
  US12/316,350
• Publication Number:
  US 20090132066A1
• Time in Patent Office: 1,152 Days
• Field of Search: 700/79, 362/562, 362/373, 449/3, 709/201, 361/623, 340/635, 340/650, 340/664, 307/112, 307/149
• US Class Current: 700/79
• CPC Class Codes: A61H 2033/0066 with low-voltage switching, e.g. using optical isolators, isolated transformers
• CPC Class Codes: A61H 2201/0176 By stopping operation
• CPC Class Codes: A61H 2201/5043 Displays
• CPC Class Codes: A61H 2201/5082 Temperature sensors
• CPC Class Codes: A61H 2201/5087 Flow rate sensors
• CPC Class Codes: A61H 33/005 Electrical circuits therefor
• CPC Class Codes: F24H 1/54 Water heaters for bathtubs or pools; Water heaters for reheating the water in bathtubs or pools
• CPC Class Codes: G05D 23/1931 to control the temperature of one space

Abstract

A spa control system designed to reduce maintenance cost by providing modular construction for major control functions, with built-in diagnostic capabilities for isolating defective spa components. Multi-colored LEDs on the spaside panel constantly report the status of each component of the spa as well as the status of the functional modules themselves. Each time a component is activated, measurements of operational parameters, such as load currents, are instantly made and evaluated so that the proper LED color can be presented at the spaside. Since major functions such as audio, LED control, wireless, and spa logic are separated into removable modules, repair of the control system requires less time and less skilled personnel. Other design improvements, such as direct monitoring of heater element temperature and the purging of pumps on an as-required-basis, enhance the spa'"'"'s overall reliability and thus reduce the need for maintenance.

Claims

1. An integrated spa control system comprising:

a spa pack housing enclosure including one or more function module cutouts and a cover;

a power distribution circuit board assembly coupled to a source of electrical power, said circuit board assembly disposed in said spa pack housing enclosure and including high voltage and high current circuit parts including one or more high voltage switching devices;

one or more electrical loads coupled to said power distribution circuit board assembly;

one or more removable function means connected to said power distribution circuit board assembly by connector means, said one or more removable function means including a removable function module including a module housing, a function circuit board assembly disposed in said module housing, said function module configured for removal and replacement through one of said function module cutouts without removal of the spa pack housing cover; and

one or more sensor means coupled directly or indirectly to one or more of said function means;

where said one or more function means includes programming means and is configured to analyze signals from applicable ones of said one or more sensor means and to energize said loads according to said signals and said programming means within said function means.

2. The system of claim 1, wherein said removable function means can be removed and disconnected from said power distribution circuit board assembly without the additional removal of other parts of the spa pack housing enclosure.

3. The system of claim 1, wherein one of said function means further comprises logic means coupled to said distribution means and in communication with others of said function means for the purpose of coordinating the activities of one or more of said other function means.

4. The system of claim 3, wherein said communication comprises a simultaneous broadcast of common operational data to one or more of said others and unique data from one or more of said others which is sent to said logic means when requested by said logic means.

5. The system of claim 1, wherein said removable function module is an audio function module, comprising an audio circuit including an FM tuner.

6. The system of claim 5, wherein said audio function module comprises one or more Class D amplifier integrated circuits, a FM tuner integrated circuit, or a DSP integrated circuit.

7. The system of claim 1, wherein said removable function module is a light control function module.

8. The system of claim 7, wherein said light control function module includes means for changing relative brightness of LEDs from one or more user interfaces.

9. The system of claim 7, wherein said light control function module includes means for changing relative brightness of LEDs according to one or more characteristics of music from audio means.

10. The system in claim 1, wherein said function module includes a wireless bus means for communicating with a Personal Computer or remote user interfaces.

11. The system in claim 1, wherein electrical components of said power distribution circuit board assembly are mounted by thru-hole construction, and all electrical components on the removable function module are low voltage, low current components which are surface mounted on a function module circuit board comprising the function board circuit board assembly.

12. The system in claim 1, wherein the module housing is a plastic housing having a gasket around a housing periphery.