Battery backup sump pump systems and methods

• US 9,885,360 B2
• Filed: 10/25/2012
• Issued: 02/06/2018
• Est. Priority Date: 10/25/2012
• Status: Active Grant

• Current Assignee: Pentair Flow Technologies LLC (Pentair Plc (Ireland))
• Original Assignee: Pentair Flow Technologies LLC (Pentair Plc (Ireland))
• Inventors: Boese, Thomas G., Bishop, Michael B., Ambrose, Jeffrey C., Emerson, John, Paton, David E., Mazza, Joseph J.
• Primary Examiner(s): Lettman, Bryan
• Assistant Examiner(s): Nichols, Charles W
• Application Number:
  US13/660,748
• Publication Number:
  US 20140119946A1
• Time in Patent Office: 1,930 Days
• Field of Search: 73299, 417 36, 417 38, 417411
• CPC Class Codes: F04B 17/06 Mobile combinations
• CPC Class Codes: F04B 23/021 the pump being immersed in the reservoir
• CPC Class Codes: F04B 49/06 Control using electricity regulating by means of floats actuating electric switches F04B49/04
• CPC Class Codes: F04B 49/08 Regulating by delivery pressure
• CPC Class Codes: F04D 15/0066 by changing the speed, e.g. of the driving engine
• CPC Class Codes: F04D 15/0218 the condition being a liquid level or a lack of liquid supply

Abstract

Embodiments of the invention provide battery backup sump pump (BBU) systems and methods. The BBU systems and methods can be used with a battery and an alternating current power source to charge the battery. The BBU systems and methods can be adapted to be a portable power source for AC and DC external devices.

Claims

1. A backup sump pump system for a sump, the backup sump pump system comprising:

a portable housing including a first half and a second half, and one of the first half and the second half including a control panel and a rechargeable battery;

a battery charger, the battery charger integrated into the portable housing;

control circuitry integrated into the portable housing, the control circuitry to be powered by a line power and when the line power is not available, the control circuitry to be powered by a battery power from the rechargeable battery, the control circuitry connected to the control panel and including a pressure transducer, the control circuitry coupled to the battery charger;

a backup sump pump connected to the control circuitry; and

a boost circuit connected to the control circuitry, the boost circuit to provide a substantially constant voltage to the backup sump pump when the line power is not available while allowing the rechargeable battery to drop to a predetermined lower voltage; and

a fluid level sensor connected to the pressure transducer, the pressure transducer to measure a pressure in the fluid level sensor to detect a rate of water level increase in the sump, and based on the measured pressure in the fluid level sensor, the control circuitry to operate the backup sump pump at a first speed when the rate of water level indicates a water level in the sump is falling, and to operate the backup sump pump at a second, higher speed when the rate of water level indicates the water level in the sump is rising required to keep up with the rate of water level increase; and

a contact sensor, the contact sensor connected to the control circuitry and coupled to the fluid level sensor to provide a signal to the control circuitry when the contact sensor comes into contact with a fluid.

2. The system of claim 1, wherein the backup sump pump is an AC backup sump pump.

3. The system of claim 1, wherein the backup sump pump is a DC backup sump pump.

4. The system of claim 1, and further comprising a wireless controller connected to the control circuitry, the wireless controller for transmitting and receiving data wirelessly for remote monitoring.

5. The system of claim 1, wherein the control circuitry is configured to adjust the speed of the backup sump pump using at least two selectable voltages.

6. The system of claim 1, wherein one of the first half and the second half including a heat sink.

7. The system of claim 1, wherein the pressure transducer substantially continuously measures the pressure in the fluid level sensor, and based on a measured pressure change, the control circuitry to adjust the speed of the backup sump pump.

8. The system of claim 7, and further comprising a voltage regulator, the voltage regulator to adjust the speed of the backup sump pump based on the measured pressure change by adjusting a voltage level output to the sump pump.

9. The system of claim 1, and further comprising a voltage input connector to supply the line power to the control circuitry.

10. The system of claim 9, wherein the voltage input connector is at least one of an AC voltage input connector and a DC voltage input connector.

11. The system of claim 1, and further comprising a DC to AC inverter, the inverter drawing a DC power from the rechargeable battery and providing an AC power to the backup sump pump.

12. A backup sump pump system comprising:

a portable housing including a first half and a second half, and one of the first half and the second half including a control panel and a rechargeable battery;

control circuitry integrated into the portable housing, the control circuitry to be powered by a line power and when the line power is not available, the control circuitry to be powered by a the rechargeable battery, the control circuitry connected to the control panel, the control circuitry including a pressure transducer;

a battery charger, the battery charger integrated into the portable housing;

a backup sump pump connected to the control circuitry;

a boost circuit connected to the control circuitry, the boost circuit to provide a substantially constant voltage to the backup sump pump when the line power is not available while allowing the rechargeable battery to drop to a predetermined lower voltage; and

a fluid level sensor, the fluid level sensor comprising an inverted cup with a sealed top and an open bottom, the inverted cup defining an inner air space;

the fluid level sensor connected to the pressure transducer, the pressure transducer to measure a pressure in the fluid level sensor, and based on the measured pressure, the control circuitry to adjust the substantially constant voltage to the backup sump pump to increase an operating speed of the backup sump pump when the measured pressure indicates a rising fluid level and decrease the operating speed of the backup sump pump when the measured pressure indicates a steady or falling fluid level; and

a contact sensor positioned near the sealed top of the fluid level sensor, the contact sensor including a pair of conductive contacts, and a pair of conduction paths extending from the inverted cup, one conduction path extending from each one of the pair of conductive contacts to the control circuitry.

13. The system of claim 12, wherein the fluid level sensor further comprises an inner pressure path extending from the inner air space, through the sealed top, and to the pressure transducer.

14. The system of claim 13, and further comprising an ambient pressure path, the ambient pressure past providing an ambient pressure to the pressure transducer.

15. A backup sump pump system comprising:

a portable housing including a first half and a second half, and one of the first half and the second half including a control panel and a rechargeable battery;

control circuitry integrated into the portable housing, the control circuitry to be powered by a line power and when the line power is not available, the control circuitry to be powered by the rechargeable battery, the control circuitry connected to the control panel, the control circuitry including a pressure transducer;

a battery charger, the battery charger integrated into the portable housing;

a backup sump pump connected to the control circuitry;

a boost circuit connected to the control circuitry, the boost circuit to provide a substantially constant voltage to the backup sump pump when the line power is not available while allowing the rechargeable battery to drop to a predetermined lower voltage; and

a fluid level sensor, the fluid level sensor comprising an inverted cup with a sealed top and an open bottom, the inverted cup defining an inner air space;

the fluid level sensor connected to the pressure transducer, the pressure transducer to measure a pressure in the fluid level sensor, and based on the measured pressure, the control circuitry to turn on the backup sump pump when the measured pressure indicates a first rate of fluid level increase and a first fluid level, the control circuitry to turn on the backup sump pump when the measured pressure indicates a second, lower rate of fluid level increase and a second, higher fluid level; and

a contact sensor positioned near the sealed top of the fluid level sensor, the contact sensor including a pair of conductive contacts, and a pair of conduction paths extending from the inverted cup, one conduction path extending from each one of the pair of conductive contacts to the control circuitry.