Systems and methods for controlling chlorinators

• US 9,885,193 B2
• Filed: 07/30/2012
• Issued: 02/06/2018
• Est. Priority Date: 07/29/2011
• Status: Active Grant

• Current Assignee: Hayward Industries, Inc.
• Original Assignee: Hayward Industries, Inc.
• Inventors: Chen, Patrick, Sawyer, Douglas, Nilsson, Michael, Denkewicz, Raymond
• Primary Examiner(s): Norris, Claire A
• Application Number:
  US13/562,128
• Publication Number:
  US 20130105403A1
• Time in Patent Office: 2,017 Days
• Field of Search: 21016711, 210 85, 210138, 210143, 210149, 2101981
• CPC Class Codes: C02F 1/008 Control or steering systems not provided for elsewhere in subclass C02F
• CPC Class Codes: C02F 1/4674 with halogen or compound of halogens, e.g. chlorine, bromine
• CPC Class Codes: C02F 2103/42 from bathing facilities, e.g. swimming pools
• CPC Class Codes: C02F 2201/006 Cartridges
• CPC Class Codes: C02F 2209/006 comprising a software program or a logic diagram
• CPC Class Codes: C02F 2209/008 comprising telecommunication features, e.g. modems or antennas
• CPC Class Codes: C02F 2209/02 Temperature
• CPC Class Codes: C02F 2209/06 pH
• CPC Class Codes: C02F 2209/40 Liquid flow rate
• CPC Class Codes: C02F 2209/445 Filter life
• CPC Class Codes: C02F 2303/04 Disinfection
• CPC Class Codes: E04H 4/1281 Devices for distributing chemical products in the water of swimming pools
• CPC Class Codes: G01N 35/00584 Control arrangements for automatic analysers
• CPC Class Codes: G05B 19/40938 Tool management
• CPC Class Codes: G05B 19/4184 characterised by fault tolerance, reliability of production system
• CPC Class Codes: G05B 2219/31095 Read write intelligent chip on workpiece, pallet, tool for data exchange
• CPC Class Codes: G05B 2219/31447 Process error event detection and continuous process image detection, storage
• CPC Class Codes: G05B 2219/31471 Operator can select a graphical screen at his will as help diagnostic
• CPC Class Codes: G05B 2219/31479 Operator select part of process he wants to see, video image is displayed
• CPC Class Codes: G05B 2219/32356 For diagnostics
• CPC Class Codes: G05B 2219/33284 : Remote diagnostic
• CPC Class Codes: G05B 2219/33287 : Program panel to program, enter data for diagnostic
• CPC Class Codes: G05B 2219/37337 : Noise, acoustic emission, sound
• CPC Class Codes: G05B 2219/49302 : Part, workpiece, code, tool identification
• CPC Class Codes: G05B 2219/49304 : Tool identification, code
• CPC Class Codes: G06F 15/00 : Digital computers in general details G06F1/00 – G06F13/00; Data processing equipment in general
• CPC Class Codes: Y02P 90/02 : Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

Systems and methods for controlling chlorinators for pools and spas are provided. A controller communicates with a processor positioned within a replaceable cell cartridge of a chlorinator, to allow for remote control and diagnosis of the chlorinator and/or cell cartridge. The cell cartridge stores, in non-volatile memory on board the cartridge, one or more parameters associated with the cartridge. The controller can obtain this information from the processor of the cell cartridge, and can use same to configure operation of the chlorinator. Information relating to remaining cell life can be updated by the controller and stored in the non-volatile memory of the cell cartridge. Electrical and software-based mechanisms are provided for ensuring operation of only compatible cell cartridges with the chlorinator. A system for remotely diagnosing errors associated with the chlorinator is also provided.

Claims

1. A system for controlling a chlorinator, comprising:

a chlorinator including a body and a replaceable chlorinator cartridge removably positionable within said body, said chlorinator cartridge including a cartridge body, a cartridge cap having a connector, a plurality of electrolytic plates within the cartridge body, a memory, and a processor in electrical communication with the plurality of plates and the memory of the cartridge;

a controller in electrical communication with said chlorinator, said controller including a control panel for allowing a user to control operation of said chlorinator,

wherein said processor of said chlorinator cartridge communicates with said controller to authenticate said chlorinator cartridge, said controller prohibiting operation of said chlorinator cartridge if said chlorinator cartridge is not authenticated;

wherein said cartridge houses said memory, said processor, and said plates; and

wherein said cartridge, said memory, said processor and said plates form a single unit removable from the chlorinator.

2. The system of claim 1, wherein said memory stores an authentication key, said processor transmitting said authentication key to said controller for subsequent authentication of said chlorinator cartridge.

3. The system of claim 2, wherein said memory stores one or more parameters relating to said chlorinator cartridge.

4. The system of claim 3, wherein said one or more parameters comprises one or more of a minimum electrical parameter associated with said chlorinator cartridge, a maximum electrical parameter associated with said chlorinator cartridge, a cell coating condition, a life expectancy associated with said chlorinator cartridge, a thermal operating parameter associated with operation of the chlorinator cartridge, a running time associated with said chlorinator cartridge, or a salinity operating parameter.

5. The system of claim 4, wherein said processor transmits said one or more parameters to said controller for subsequent processing by said controller.

6. The system of claim 1, wherein said control panel further comprises means for indicating operational, status, or diagnostic information relating to the chlorinator.

7. The system of claim 6, wherein said control panel further comprises a control knob for controlling chlorination output of the chlorinator.

8. The system of claim 7, wherein said control panel further comprises a plurality of switches for controlling operation of the chlorinator.

9. The system of claim 1, wherein said controller further comprises a movable cover for covering the control panel.

10. The system of claim 1, wherein the control panel is mountable at a location remote from said chlorinator.

11. The system of claim 1, wherein said chlorinator cartridge further comprises at least one sensor for sensing a condition relating to water being chlorinated by the chlorinator.

12. The system of claim 1, wherein said chlorinator cartridge further comprises a shaped electrical connector for electrical connection to a cable interconnecting said chlorinator with said controller.

13. A method for controlling a chlorinator, comprising the steps of:

establishing a communications link between a chlorinator and a controller, the chlorinator including a body and a replaceable chlorinator cartridge removably positionable within said body, said chlorinator cartridge including a cartridge body, a cartridge cap having a connector, a plurality of electrolytic plates within the cartridge body, a memory, and a processor in electrical communication with the plurality of plates and the memory of the cartridge, wherein said cartridge houses said memory, said processor, and said plates;

wherein said cartridge, said memory, said processor and said plates form a single unit removable from the chlorinator;

retrieving an authentication key from the memory of the chlorinator cartridge removably positioned within said chlorinator;

transmitting the authentication key from said chlorinator to said controller;

processing the authentication key at the controller to determine whether the chlorinator cartridge is authenticated; and

operating the chlorinator using the controller if the cartridge is authenticated by the controller.

14. The method of claim 13, further comprising prohibiting operation of the chlorinator if the cartridge is not authenticated by the controller.

15. The method of claim 13, further comprising accessing one or more parameters stored in said memory of said chlorinator cartridge using said controller.

16. The method of claim 15, further comprising adjusting operation of said chlorinator or said controller based upon said one or more parameters.

17. The method of claim 13, further comprising reading run time information from said memory of said chlorination cartridge using said controller and determining whether said run time exceeds a threshold.

18. The method of claim 17, further comprising indicating to a user who is using the controller that said chlorination cartridge should be replaced if said run time exceeds said threshold.

19. A chlorinator comprising:

a chlorinator body including a first flow port and a second flow port on opposite sides of the chlorinator body and being coaxially aligned such that the first flow port and the second flow port share a first axis extending through centers of the first flow port and the second flow port; and

a replaceable chlorinator cartridge removably positionable within said chlorinator body along a second axis transverse to the first axis,

said chlorinator cartridge including a plurality of electrolytic plates and at least one circuit element in electrical communication with said plurality of plates,

said replaceable cartridge housing said plurality of plates and said at least one circuit element,

said cartridge, said plurality of plates and said at least one circuit element forming a single unit removable from said chlorinator body, and

said plurality of plates of said chlorinator cartridge positioned along said first axis such that water flows along said first axis extending through said first flow port, through said plurality of plates housed in said chlorinator cartridge, and out of the second flow port.

20. The chlorinator of claim 19, wherein said chlorinator cartridge further comprises a memory for storing an authentication key, a processor transmitting said authentication key to a controller for subsequent authentication of said chlorinator cartridge.

21. The chlorinator of claim 20, wherein said memory stores one or more parameters relating to said chlorinator cartridge.

22. The chlorinator of claim 21, wherein said one or more parameters comprises one or more of a minimum electrical parameter associated with said chlorinator cartridge, a maximum electrical parameter associated with said chlorinator cartridge, a cell coating condition, a life expectancy associated with said chlorinator cartridge, a thermal operating parameter associated with operation of the chlorinator cartridge, a running time associated with said chlorinator cartridge, or a salinity operating parameter.

23. The chlorinator of claim 22, wherein said processor transmits said one or more parameters to said controller for subsequent processing by said controller.

24. The chlorinator of claim 19, wherein said chlorinator cartridge further comprises at least one sensor for sensing a condition relating to water being chlorinated by the chlorinator.

25. The chlorinator of claim 19, wherein said chlorinator cartridge further comprises a shaped electrical connector for electrical connection to a cable interconnecting said chlorinator with said controller.