Control algorithm of variable speed pumping system

• US 9,605,680 B2
• Filed: 07/08/2014
• Issued: 03/28/2017
• Est. Priority Date: 08/26/2004
• Status: Active Grant

• Current Assignee: Danfoss Power Electronics A/S (Danfoss A/S), Pentair Water Pool And Spa Incorporated (Pentair Plc (Ireland))
• Original Assignee: Danfoss Drives A/S (Danfoss A/S), Pentair Water Pool And Spa Incorporated (Pentair Plc (Ireland))
• Inventors: Robol, Ronald B., Yahnker, Christopher, Stiles, Robert W. Jr., Berthelsen, Lars Hoffmann, Cox, Everett, Steen, Donald, Murphy, Kevin, Hruby, Daniel J., Westermann-Rasmussen, Peter, Kjaer, Gert, Harvest, Nils-Ole, Woodcock, Walter Jr., Runarsson, Einar Kjartan, Hansen, Arne Fink, Morando, Alberto, Lungeanu, Florin
• Primary Examiner(s): Fennema, Robert
• Assistant Examiner(s): STEVENS, THOMAS H
• Application Number:
  US14/325,887
• Publication Number:
  US 20140322030A1
• Time in Patent Office: 994 Days
• Field of Search: 417/175, 417/199.2, 700/282
• US Class Current: 1/1
• 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 a pool or spa application that pumps water, the pumping system comprising:

a pump that pumps water through the pool or spa;

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 has become initially primed,

the controller indicating a priming alarm if the pumping system has not become initially primed before reaching a maximum priming time allotment;

wherein the maximum priming time allotment is a fixed time period.

2. The pumping system of claim 1 wherein the controller determines the current flow rate based on the input power to the motor without relying on a flow rate sensor.

3. The pumping system of claim 1 wherein the pump, the motor, and the controller are coupled together in a single pump unit.

4. The pumping system of claim 1 wherein the controller is a variable frequency drive.

5. The pumping system of claim 1 wherein the controller further determines whether the pumping system has lost prime after the pumping system has become initially primed before reaching the maximum priming time allotment, 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 if the pumping system is no longer primed 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.

6. A pumping system for a pool or spa application that pumps water, the pumping system comprising:

a pump that pumps water through the pool or spa;

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 riming flow value in order to determine whether the pumping system has become initially primed,

the controller indicating a priming alarm if the pumping system has not become initially primed before reaching a maximum priming time allotment;

wherein the maximum priming time allotment is a time period between activating the motor and a fixed time period when the pump is primed.

7. A pumping system for a pool or s a application that pumps water, the pumping system comprising:

a pump that pumps water through the pool or spa;

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 has become initially primed,

the controller indicating a priming alarm if the pumping system has not become initially primed before reaching a maximum priming time allotment;

wherein the controller performs a second operation in which the controller determines a priming status and generates a priming dry alarm subsequent to a first operation in which the controller determines that the pump is initially primed.

8. A pumping system for a pool or spa application that pumps water, the pumping system comprising:

a pump that pumps water through the pool or spa;

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 adapted to receive a time start indication corresponding to a start time at which a start is activated to begin repetitive operation of a filter mode,

a time primed indication corresponding to a primed time at which the current flow rate is determined to be above a priming flow value, and a maximum priming time allotment,

the controller indicating a priming alarm if the controller has received the time start indication and has not received the time primed indication prior to the maximum priming time allotment passing after the start time.

9. The pumping system of claim 8 wherein the controller repeatedly compares the current flow rate to the priming flow value after the time start indication and before the passing of the maximum priming time allotment.

10. A method of operating a pumping system for a pool or spa application that pumps water, the pumping system comprising a controller in communication with a motor, the motor coupled to a pump that pumps water through the pool or spa, the method comprising the following sequential steps:

a) activating a start to begin operation of a filter mode;

b) determining whether the pumping system is primed and proceeding to step c) if the pumping system is primed and step d) if the pumping system is not primed;

c) if the pumping system is primed in step b), continuing operation of the filter mode without displaying a priming alarm;

or

if the pumping system is not primed in step b), performing the following sequential steps;

d) performing a flow control process and determining whether the pumping system has become primed;

e) repeating step d) if the pumping system has not become primed as a result of step d); and

f) after a maximum priming time allotment has passed from step a), displaying a priming alarm if the pumping system has not become primed as a result of step d),

wherein determining whether the pumping system is primed and determining whether the pumping system has become primed each comprise determining a current flow rate based on an input power to the motor and determining whether the current flow rate is above a priming flow value.

11. The method of claim 10, the method comprising the following additional sequential steps:

g) if the pumping system is determined to be primed as a result of steps a) through f), such that the priming alarm has not been displayed, calculating a shaft power based on a hardware input including at least one of input power and motor speed; and

h) if the shaft power is at least approaching zero for at least about ten seconds, indicating a priming dry alarm that the pumping system has lost the prime determined in steps a) through f).