Method of controlling a pump and motor

• US 10,590,926 B2
• Filed: 01/31/2017
• Issued: 03/17/2020
• Est. Priority Date: 06/09/2009
• Status: Active Grant

• Current Assignee: Pentair Flow Technologies LLC (Pentair Plc (Ireland))
• Original Assignee: Pentair Flow Technologies LLC (Pentair Plc (Ireland))
• Inventors: Kidd, Melissa Drechsel, Genaw, William James, Pasche, Michael, Baase, II, Gary T.
• Primary Examiner(s): Bertheaud, Peter J
• Application Number:
  US15/421,251
• Publication Number:
  US 20170234117A1
• Time in Patent Office: 1,141 Days
• CPC Class Codes: F04B 17/03 driven by electric motors
• CPC Class Codes: F04B 2203/0204 Frequency of the electric current
• CPC Class Codes: F04B 2205/04 Pressure in the outlet chamber
• CPC Class Codes: F04B 2205/05 Pressure after the pump outlet
• CPC Class Codes: F04B 47/00 Pumps or pumping installations specially adapted for raising fluids from great depths, e.g. well pumps by using positive or negative pressurised fluid medium acting directly on the liquid to be pumped F04F1/00
• CPC Class Codes: F04B 47/06 having motor-pump units situated at great depth
• CPC Class Codes: F04B 49/06 Control using electricity regulating by means of floats actuating electric switches F04B49/04
• CPC Class Codes: F04B 49/065 and making use of computers
• CPC Class Codes: F04B 49/08 Regulating by delivery pressure
• CPC Class Codes: F04B 49/10 Other safety measures
• CPC Class Codes: F04D 13/08 for submerged use
• CPC Class Codes: F04D 13/10 adapted for use in mining bore holes
• CPC Class Codes: F04D 15/0066 by changing the speed, e.g. of the driving engine
• CPC Class Codes: F04D 15/0077 Safety measures F04D15/02 takes precedence
• CPC Class Codes: F04D 15/0088 Testing machines
• CPC Class Codes: F04D 15/0209 responsive to a condition of the working fluid F04D15/029 takes precedence
• CPC Class Codes: F04D 15/0236 Lack of liquid level being detected by analysing the parameters of the electric drive, e.g. current or power consumption
• CPC Class Codes: F04D 15/0254 the condition being speed or load

Abstract

A variable frequency drive system and a method of controlling a pump driven by a motor with the pump in fluid communication with a fluid system is provided. The method includes monitoring a pressure in the fluid system, monitoring and adjusting an operating frequency of the motor to maintain the pressure at a pressure set point, and, based on the monitored operating frequency, causing the pump to temporarily boost the pressure in the fluid system to a temporary boost set point for a first time period. The method also includes determining whether the temporarily boosted pressure in the fluid system stays above the pressure set point for a second time period and causing the pump to enter a sleep mode when the temporarily boosted pressure stays above the pressure set point through the second time period.

Claims

1. A method of controlling a pump driven by a motor, the pump in fluid communication with a fluid system, the method comprising:

monitoring a pressure in the fluid system;

monitoring and adjusting an operating frequency of the motor to maintain the pressure at a pressure set point;

based on the monitored operating frequency, causing the pump to temporarily boost the pressure in the fluid system to a temporary boost set point for a first time period, the temporary boost set point being greater than the pressure set point;

determining whether the temporarily boosted pressure in the fluid system stays above the pressure set point for a second time period; and

causing the pump to enter a sleep mode when the temporarily boosted pressure stays above the pressure set point through the second time period.

2. The method of claim 1 and further comprising causing the pump to resume normal operation when the temporarily boosted pressure drops below the pressure set point within the second time period.

3. The method of claim 1 and further comprising monitoring the pressure in the fluid system while the pump is in the sleep mode and determining whether the pressure in the fluid system reaches a wakeup pressure, the wakeup pressure being less than the pressure set point.

4. The method of claim 3 and further comprising causing the pump to leave the sleep mode when the pressure drops below the wakeup pressure.

5. The method of claim 1, wherein the temporary boost set point is three pounds per square inch above the pressure set point.

6. The method of claim 1, wherein the temporary boost set point is modifiable by a user.

7. The method of claim 1, wherein causing the pump to enter the sleep mode includes stopping the motor.

8. The method of claim 1, wherein causing the pump to enter the sleep mode includes setting the operating frequency of the motor to zero Hertz.

9. A controller for a pump driven by a motor, the pump in fluid communication with a fluid system, the controller comprising:

a control panel including a display, directional buttons, and an enter button; and

a variable frequency drive circuit that controls operation of the pump, the variable frequency drive circuit connected to the control panel, the variable frequency drive circuit configured to;

monitor a pressure in the fluid system,

monitor and adjust an operating frequency of the motor to maintain the pressure at a pressure set point, the pressure set point being programmable by a user using the directional buttons and the enter button,

based on the monitored operating frequency, cause the pump to temporarily boost the pressure in the fluid system to a temporary boost set point for a first time period, the temporary boost set point being programmable by a user using the directional buttons and the enter button,

determine whether the temporarily boosted pressure in the fluid system stays above the pressure set point for a second time period, and

cause the pump to enter a sleep mode when the temporarily boosted pressure stays above the pressure set point through the second time period.

10. The controller of claim 9, wherein the variable frequency drive circuit is configured to cause the pump to resume normal operation when the temporarily boosted pressure drops below the pressure set point within the second time period.

11. The controller of claim 9, wherein the variable frequency drive circuit is configured to monitor the pressure in the fluid system while the pump is in the sleep mode and determine whether the pressure in the fluid system reaches a wakeup pressure, the wakeup pressure being less than the pressure set point, the wakeup pressure being programmable by a user using the directional buttons and the enter button.

12. The controller of claim 11, wherein the variable frequency drive circuit is configured to cause the pump to leave the sleep mode when the pressure drops below the wakeup pressure.

13. The controller of claim 9, wherein the variable frequency drive circuit is configured to cause the pump to enter the sleep mode by setting the operating frequency of the motor to zero Hertz.

14. The controller of claim 9, wherein the control panel includes a stop button, the variable frequency drive circuit disabling the pump when the stop button is engaged.

15. The controller of claim 9, wherein the display is a liquid crystal display.