Abstract:
A pump control system includes a controller coupled to first and second pressure sensors. The sensors couple serial pressure related information to the controller. The controller can evaluate respective liquid levels, in response to received pressure related information from the sensors. A current sensor coupled to the controller can provide signals indicative of operation of one or more pumps coupled to the controller. The controller includes circuits to detect the presence of predetermined faults and to emit an audible fault indicator in response thereto.

Description:
FIELD 
     The invention pertains to multiple pump control units. More particularly, the invention pertains to computer based control units which can control multiple pumps in response to sensed liquid levels. 
     BACKGROUND 
     Various types of sump pump control units are known. Many of these units are intended to work with float switches. While useful, such switches are known to have limited life-times in part due to pump motor turn on/turn off currents, and are inconvenient when liquid on-off levels are being set. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an over-all diagram of one embodiment of the invention; 
         FIG. 2  is a block diagram illustrating additional aspects of the embodiment of  FIG. 1 ; 
         FIG. 3  is a diagram of an exemplary sensor; and 
         FIG. 4  is a diagram of an exemplary pump switching circuit. 
     
    
    
     DETAILED DESCRIPTION 
     While embodiments of this invention can take many different forms, specific embodiments thereof are shown in the drawings and will be described herein in detail with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention, as well as the best mode of practicing same, and is not intended to limit the invention to the specific embodiment illustrated. 
     In one aspect of the invention, a microprocessor controlled residential simplex or duplex pump controller utilizes digital water level sensors. When paired with either one sump pump or two sump pumps, the controller accurately monitors the water levels within the sump pit or similar environment and activates the appropriate pump accordingly. 
     A plurality of pumps can be operated individually, operating one at a time, from a single residential wiring circuit. This creates pumping redundancy should one of the pumps happen to fail to operate and simplifies the installation by eliminating the necessity for an additional branch circuit feeder for the second pump. 
     In another aspect of the invention, a main controller unit is coupled to two digital level sensors. Two push button switches on a cover of a housing allow the user to adjust and set the pump(s) turn on level. By incorporating this feature, the user can adjust the level at which the pump will activate without having to change the height of the digital level sensor, as in the case of traditional float switches. This feature also allows the unit to be used effectively in small volume sump pits as well as large volume sump pits. Sump pumps can now be efficiently cycled within their working environment by effortlessly selecting the appropriate pump turn on height. By minimizing the actual number of pump turn on cycles the life expectancy of the pump(s) can be further maximized and energy conserved. 
     The controller accurately determines the height of the water within a given sump application, based on information acquired from the two digital level sensors. The digital level sensors accurately measure the height of the water within the sump pit and digitally communicate those values to the host controller by means of a serial communications protocol transmitted via a serial communications link. 
     A separate microprocessor within the digital float sensors samples analog data from a strain gauge which electro-mechanically converts the water pressure to an electrical resistance. Because water pressure is directly proportional to the water height, the electrical resistance of the strain gauge is also proportional to the water height. The resistance of the strain gauge is measured by means of a resistive bridge network and is further amplified and conditioned by an operational amplifier network before passing into the microprocessors analog to digital converter input. 
     Within the microprocessor, the analog voltage value, which is proportional to the water level, is converted to a numerical (binary) value which is subsequently scaled to produce a water level to binary ratio of 0.1 inches of height per single bit of accuracy. An 8 bit value of xFF, or 255 base 10, would indicate a water level of 25.5 inches. Similarly, an 8 bit value of x00, or 0 base 10, would indicate a water level of 0.00 inches 
     By allowing the water level sensing to be performed digitally within each float sensor, the unit can use a hardware differential signaling communications method to robustly and accurately transfer the digital water height information from the level sensors to the host processor. This provides for an accurate measurement of the water level in the presence of radiated electrical noise, which is often inherent in AC (alternating current) motor applications. Electrical noise is most commonly generated during motor turn on and turn off events. 
     The digital level sensors communicate water levels to the host controller digitally by means of a software driven serial communications link. This software feature, encoded within every digital level sensor and the host microprocessor allows for robust data delivery by means of cyclical redundancy checks as well as timer based fault exceptions. This method can be used to communicate water height data, as well as internal sensor status data, to the host controller accurately. 
     Traditionally, sump pumps have often been started by means of a mechanical switch. The mechanical switch design often uses a set of electrical contacts which close under a given water height scenario, thereby activating the sump pump. Due to the alternating nature of the electrical voltage source from the utility, large voltage differentials could possibly be present across the mechanical switch contacts prior to turning on a pump. When a pump is suddenly turned on under these conditions, large transient current surges could be expected as the motor begins to rotate. These transient surges often cause heating of the electrical contacts which, over time, effectively reduce the life time of the switch. This condition is further amplified when a mechanical switch attempts to open and turn off the pump. 
     As is well known, electrical motors are largely inductive in nature. The nature of an inductor is to resist sudden changes in current by means of its induced magnetic field. When an inductor circuit which was passing current is suddenly opened, its magnetic field attempts to maintain the current flow before gradually diminishing. As this occurs, a voltage is generated across the inductor which is directly proportional to the time varying change of current through it. This voltage can be described by the equation V L =Ldi/dt (Eq. 1). This formula states the voltage induced across an inductor is proportional to the inductance of the inductor times the time rate of change of the inductor current. 
     When a mechanical switch suddenly opens an inductive motor load, the time rate of change of the current flow can be very large. This value, multiplied by the motors internal inductance, induces a large voltage transient across the mechanical switch contacts. This transient often causes arcing of the contacts which, over time, can cause the switch to wear and ultimately fail. It is well known in the sump pump industry that the cause of most pumping failures occurs when the pumps switch fails. 
     Embodiments of the invention effectively eliminate the problem of switching transients and contact arcing by incorporating both a solid state switching device in parallel with an electrical relay. When a pump is called for, the turn on cycle begins by enabling the solid state device, or triac. The nature of the triac in our design is to switch on a load under low voltage conditions. By starting the pump motor from a low voltage potential, both radiated and conducted electrical noise have been dramatically reduced. 
     Further, the absence of electrical contacts during the starting of the motor phase reduces the probability of switch failure over an extended period of time. To reduce heat and power dissipation in the triac after a pump has started, a relay is activated whose contacts close across the switching contacts of the triac. Because the voltage potential across the triac is very low when it is enabled, the relay contacts also close across a low voltage potential thereby reducing the probability of arcing and extending the life of the relay. When used in this manner, the triac/relay time delayed switching method provides a very reliable and effective means for enabling a sump pump and increasing pumping operations. 
     Additional benefits to this switching method are seen when attempting to turn off a sump pump. At the beginning the turn off sequence, the relay is turned off first and its contacts are opened. As the relays contacts begin to open, they open across the triacs switching contacts which are still at a very low impedance and voltage. Pump current is instantly diverted through the triac, allowing for an arc free power transition in the relay. This, again, allows for very low electrical noise generation and extends the life of the relay contacts increasing overall pump operations. 
     After a predetermined amount of time, the triac is also disabled. Given the electrical nature of this device, the current passing through it is terminated at a value approaching zero amps. If we look again at Eq. 1 above, and substitute 0 in for the di term, we get a resulting V L  of zero volts. This means that the probability of an excessive voltage spike across the switching components is greatly reduced at pump turn off reducing the probability of electrical noise and increasing the reliability and longevity of the pump system. 
     Referring to  FIGS. 1 ,  2  an embodiment of the invention, a control system  10 , can be carried in a housing  12 . Housing  12  can support a power on indicator, such as an LED,  14  as well as an alarm indicating indicator  16 . 
     A first pump P 1  can be coupled to the system  10  via an AC-type receptacle  18 . Housing  12  can also carry a pump  1  running LED indicator  20 . A first digital level sensor  22  can be coupled to the housing  12  via a connector. A remote alarm output contact, for example a relay contact  24  can be accessed at a connector on the housing  12 . 
     A second, high level, digital level sensor  26  can be coupled to the housing  12  via a connector. A test/reset pushbutton, for a switch,  28  can also be carried by housing  12 . Housing  12  can also carry a pump  2  running LED indicator  30 . 
     A second pump P 2  can be coupled to the system  10  via an AC-type connector or receptacle  32 . AC power can be input, via a cord, at  34 . Switch actuators  36 ,  38  can be used to decrement or increment a level set point. A liquid crystal display  40  can be carried by housing  12  to provide output messages visually. 
     A controller  50  can be implemented with a programmable processor  50   a , associated executable instructions, software  50   b  pre-stored on a computer readable medium and interface circuits and storage or memory units  50   c . Pumps P 1 , P 2  can be driven by respective switching circuits  54   a ,  54   b . A current sensor  56  makes it possible to determine if one or both pumps are running. 
       FIG. 3  illustrates an exemplary diagram of one of the sensors, such as  22 ,  26 . The sensors, such as  22 ,  26  can include a sealed housing  60 , which would be configured as a float switch. A strain gage, which might be implemented as a bridge,  62  is carried in housing  60  and responsive to external water pressure. Output from the strain gage  62  can be processed, in one or more operational amplifier circuits, such as  64 . A processed pressure indicative signal can be coupled on a line  64   a  to a programmed processor  66  which has an A/D input port  66   a . Processed digital signals, representative of sensed pressure can be coupled by processor  66  to link interface circuits  68 . In a disclosed embodiment, serial digital output signals on a line  68   a  can be coupled to controller  50 . 
       FIG. 4  illustrates a switching configuration usable in the pump switching circuits  54   a ,  54   b . Circuits  54   a,b  can include a normally open relay  70  with contacts coupled in parallel across a solid state switch  72 . 
     Further, in accordance with the invention, the controller  50  is able to determine whether there is one pump, such as P 1 , or two pumps P 1 , P 2  connected to it upon initial power up of the unit using current sensor  56 . When the controller  50  is initially powered, the host microprocessor  50   a  executes a setup process. The setup process begins by displaying the product name on the liquid crystal display, or LCD  40 . The processor  50   a  then continues by enabling the P 1  switching circuit  54   a  and taking measurements of the pump  1  receptacle current, via current sensor  56 , over a specified sample period. 
     When the period has expired, the pump  1 , P 1 , switching circuit  54   a  is deactivated and the same process is repeated for pump  2 , P 2 . When the pump  2  receptacle current sampling period has expired, the host microprocessor  50   a  determines whether there are one or two pumps connected to the unit  10  by comparing each of the measured current values to a predetermined threshold value. If the measured current of each pump test is greater than or equal to this threshold value, then it is determined that the respective pump is indeed connected to its respective receptacle on the housing  12 . 
     The setup process continues by displaying which pump or pumps are available and storing the information in the processor&#39;s flash memory  50   c . It then displays whether the unit  10  is functioning as a simplex controller or a duplex controller based on the number of pumps available. Simplex mode operation occurs when only one pump is available upon setup. Similarly, duplex mode operation commences when two pumps are available upon setup. 
     This setup sequence occurs each time the unit  10  is initially powered up. In the event of a power failure, the Ion Genesis will perform the setup sequence and determine, once again, how many pumps it is controlling, and consequently, what mode to operate in. This feature can be especially useful if one is attempting to add an extra pump or remove an existing pump from the pump control system  10 . If one wishes to amend their present pump setup, they can simply press the RESET pushbutton switch  28  located on the front of the unit  10  or sequence the power to the unit by removing and reinstalling the power cord. Either method ensures that the unit  10  will enter the setup mode and establish the proper mode of operation automatically. 
     Upon completion of the initial setup mode sequence the controller  50  can execute internal diagnostic software routines which target proper LCD operation, proper digital sensor operation, and proper load current operation. Should a problem arise in one or more of these areas, the control circuits  50  dynamically determine a new mode of operation. 
     If it is determined that no faults have been detected or logged by the error checking algorithms, then Normal Operation Mode is entered. In this mode, the pump controller  50  works by monitoring the water level in the sump environment and comparing that value to the user-adjustable pump turn on level. If the level of water detected is equal to the pump turn on level then pump is activated. 
     An advantageous feature of the system  10  is the ability of the user to dynamically make adjustments to the pump turn on level. The user can adjust the turn-on height of the pump(s) in half-inch increments by simply pressing either the UP Arrow push button switch  38  or the DOWN Arrow push button switch  36 . The flexibility of this design and feature allows the user to tailor their pumping cycles quickly and easily without the necessity of manually adjusting the position of the level sensor. The sump pit cover can remain intact and undisturbed saving time and reducing the effort needed to make the necessary adjustments. 
     The ability to quickly adjust the pump turn on set point is beneficial to many fluid pumping scenarios. If installed in a typical residential sump pit, which is often tall and narrow, the user can adjust the pump turn on set point to a higher level allowing for fewer pump cycles with a fixed fluid flow rate into the sump pit. Likewise, if installed in a larger diameter sump pit environment where the volume of water is inherently large, the user could adjust the pump turn on height to a lower level ensuring that the level of fluid in the pit remains relatively low as a constant. This may be extremely useful when a low GPM (gallon per minute pump) is used in a large sump pit environment. 
     When a user changes the pump turn on set point value, the new value is stored in the host microprocessor&#39;s flash memory  50   c  after 3 seconds of remaining unchanged. No values are saved while the user is making adjustments to the pump turn on level. This feature is unique and beneficial as it provides a static and nonvolatile set point should power be lost or removed and subsequently restored to the Ion Genesis. The user does not have to re-adjust the pump turn on level when power is restored after a power failure, as the value has been retained. 
     In continuing with the normal pump operation mode, when a pump has been energized as described above several key areas of the pump&#39;s operations are scrutinized to determine whether the pump is operating properly. During pump operation, the pump current is sampled and processed to ensure it is operating within a predetermined range of current values. Should the measured pump current exceed the maximum current threshold value or fall below the minimum pump current threshold value, a pump current fault is latched within the host microprocessor for subsequent fault handling. 
     Because the controller  50  has the real-time ability to determine the precise water level in the sump environment, a level trending process, implemented by the processor  50   a  executing instructions  50   b , can be included to determine whether the activated pump is indeed causing the fluid level in the sump to change in a negative direction over time. Under normal operating conditions, if a pump is running properly and the discharge piping is unobstructed, the volume of fluid in the pit is removed and thereby reduced at a rate equal to the GPM of the pump minus the rate of volume of water entering the pit at that instance. In this regard, sensed liquid levels can be stored and compared over a period of time. 
     By monitoring the rate at which the water level changes, the controller  50  can determine whether a pump is operating at an inadequate or insufficient level. Should it be determined that a pump is not performing adequately, a pump trending fault is latched within the host microprocessor for subsequent fault handling. 
     If it is determined that none of the above fault scenarios have occurred, then the pump can be disabled when the water level in the sump has reached a predetermined, static, threshold level. This level can be set to 2″, but can be altered by changing a static constant in the control software  50   b.    
     One of the advantages of digital based fluid sensing and microprocessor control is the ability to establish process control algorithms for monitoring a plurality of dynamic state variables throughout a system. As described above, the controller  50  is capable of monitoring many system variables including pump current, digital sensor data and communications, and digital sensor internal diagnostics. Additionally, the controller  50  is capable of responding to a variety of fault scenarios should they occur. 
     In a disclosed, exemplary embodiment, the controller  50  can group the various alarm states into two priority categories. The first category contains standard priority alarms and the second category contains high priority alarms. When an alarm is initially activated, it&#39;s priority is determined and a piezo alarm output device  52  is activated. 
     The rate at which the piezo tone repeats itself it is determined by the priority of the alarm. If the alarm is a standard priority alarm, the piezo alarm tone repeats at a ¼ second rate. If the alarm is a high priority alarm, the piezo tone repeats at a faster ⅛ second rate. This feature allows the user to audibly determine the fault priority status of the controller  50  without the need for visual clarification from the LCD display  40 . The rates can be varied. 
     Fault #1: 5 Minute Timer Run Fault—This fault is set, or latched, when a pump has been running continuously for a duration of 5 minutes. Possible causes for this fault include, but are not limited to, a broken or stalled impeller or an obstruction of the pump&#39;s discharge pipe. Should any of the above conditions arise, the controller  50  enters the standard priority alarm mode thereby activating the piezo alarm tone alerting the user to the potential problem. The alarm type is displayed on the LCD display  40  allowing the user to recognize the fault and correct the situation accordingly. 
     If the system was running in duplex mode at the time the fault occurred, the pump that was running is turned off and the next available pump is turned on to continue the pumping cycle. This fault persists until the pump cycle has been terminated by the digital level sensor. 
     Fault #2: Pump Failed Fault—This fault is latched when a pump start cycle has been initiated and the pump current falls below a predetermined threshold level. Possible causes for this fault include, but are not limited to, the pump being unplugged from the unit  10  while it was operating, the pump&#39;s internal thermal fuse opening, an over-current protection device on the pump opening, or possibly an internal failure of the power switching components within the controller. Should any of the above conditions arise, the controller  50  enters the standard priority alarm mode thereby activating the piezo alarm  52  thereby generating a tone alerting the user to the potential problem. 
     The alarm type is displayed on the LCD display  40  allowing the user to recognize the fault and correct the situation accordingly. If the system was running in duplex mode at the time the fault occurred, the pump that was running is turned off and the next available pump is turned on to continue the pumping cycle. The Pump Failed Fault also triggers the one of the controller&#39;s external relay contacts, such as  24 , allowing the fault to be recorded and tended to by the user&#39;s home alarm monitoring system, if connected. 
     Fault #3: Pump Current Detected Fault—This fault is latched when the controller  50  determines that there is current being drawn from one or more of the pump receptacles with none of the power switching devices, such as  54   a ,  54   b , being activated. Possible causes for this fault include, but are not limited to, one or more of the triacs and/or relay contacts being shorted closed in the circuits  54   a ,  54   b . This is a typical failure mode of triac semiconductors if they have been over-stressed due to thermal power dissipation or if their maximum operating voltage has been exceeded. This can also occur with relay contacts if they are switching inductive loads where large voltage transients are allowed to occur. 
     Should any of the above conditions arise, the controller  50  enters the standard priority alarm mode thereby activating the piezo alarm  52  to generate an alarm tone alerting the user to the potential problem. The alarm type is displayed on the LCD display  40  allowing the user to recognize the fault. Should this fault occur, the system  10  can be evaluated and repaired, as needed. 
     Fault #4: Pump Trending Fault—This fault is latched when the controller  50  determines that discharge rate of the active pump has fallen below a predetermined value. Possible causes for this fault include, but are not limited to, excessive water flow into the sump environment at or exceeding the discharge capacity of the pump, a broken or stalled impeller, or an obstruction of the pump&#39;s discharge pipe. Should any of the above conditions arise, the controller  50  enters the standard priority alarm mode thereby activating the piezo alarm tone alerting the user to the potential problem. 
     The alarm type is displayed on the LCD display  40  allowing the user to recognize the fault and correct the situation accordingly. If the system was running in duplex mode at the time the fault occurred, the pump that was running is turned off and the next available pump is turned on to continue the pumping cycle. This fault persists until the pump cycle has been terminated by the digital level sensor, such as  22 . 
     Fault #5: Digital Sensor Fault—This fault is latched when either of the following conditions arise: If there are 8 consecutive float communication failures of the controller  50  and either of the digital level sensors  22 ,  26  then a Digital Sensor Fault is latched. Possible causes for this fault include, but are not limited to, accidentally unplugging one or more of the sensors from the Ion Genesis controller, a loose connection between one or more the sensors  22 ,  26  and the controller  50 , a break in one or more of the sensor&#39;s conductors, or an internal error within the digital level sensor. Should this alarm occur, the controller  50  enters a high priority alarm mode thereby activating the piezo alarm tone alerting the user to the potential problem. The alarm type is displayed on the LCD display  40  allowing the user to recognize the fault. This fault persists until the communication between the controller  50  and the respective digital level sensor  22 ,  26  is re-established. 
     Alternately, if either of the digital level sensor&#39;s processors experience an internal fault condition then a Digital Sensor Fault is latched. Possible causes for this fault include, but are not limited to, over temperature of the digital sensor, improper operating voltage of the digital sensor, or invalid CRC checksum error within the received communication packet. Should this alarm occur, the controller  50  enters the high priority alarm mode thereby activating the piezo alarm  52  which generates an alarm tone alerting the user to the potential problem. The alarm type is displayed on the LCD display  40  allowing the user to recognize the fault. This fault persists until all faults are cleared within both of the digital level sensors  22 ,  26 . 
     Fault #6: High Water Sensor Called For Fault—This fault is latched when the high water sensor detects the presence of water approximately 2 inches above it&#39;s calibrated 0 inch set point. Possible causes for this fault include, but are not limited to, excessive water flow into the sump environment at or exceeding the discharge capacity of the pump, a broken or stalled impeller, or an obstruction of the pump&#39;s discharge pipe. Should any of the above conditions arise, the controller  50  enters the high priority alarm mode thereby activating the piezo alarm tone alerting the user to the potential problem. 
     The alarm type is displayed on the LCD display  40  allowing the user to recognize the fault and correct the situation accordingly. If the system was running in duplex mode at the time the fault occurred, the pump that was running is turned off and the next available pump is turned on to continue the pumping cycle. This fault persists until the water level falls to approximately 1.5 inches above the high water sensor&#39;s calibrated 0 inch set point. 
     Fault #7: High Water Sensor Mode—This fault is latched when either of the following conditions arise: A: If there are 8 consecutive float communication failures between the controller  50  and the respective digital level sensor  22 ,  26 . Possible causes for this fault include, but are not limited to, accidentally unplugging the digital level sensor  22 ,  26  from the controller  50 , a loose connection between the digital level sensors, such as  22 ,  26  and the controller  50 , a break in one or more of the sensor&#39;s conductors, or an internal error within a digital level sensor  22 ,  267 . Should this alarm occur, the controller  50  can enter the high priority alarm mode thereby activating the piezo alarm tone alerting the user to the potential problem. The alarm type is displayed on the LCD display  40  allowing the user to recognize the fault. This fault also causes the controller  50  to enter and operate in a separate control mode, allowing the pump(s) P 1 , P 2  to be cycled by the alarm float only. This fault, as well as control mode, persists until the communication between the controller  50  and the respective digital level sensor  22 ,  26  is re-established. 
     Alternately, this fault is detected if the measured high water sensor value is greater than or equal to the measured digital sensor value plus one inch. Possible causes for this fault include, but are not limited to, the high alarm sensor being installed below the digital level sensor. Should this alarm occur, the controller  50  enters the high priority alarm mode thereby activating the piezo alarm tone alerting the user to the potential problem. The alarm type is displayed on the LCD display  40  allowing the user to recognize the fault. 
     This fault also causes the controller  50  to enter and operate in a separate control mode, allowing the pump(s) to be cycled by the alarm float  26  only. This fault, as well as the respective control mode, persists until the measured value from the high water sensor is less than the measured value from the digital control sensor. 
     Embodiments of the invention exhibit a variety of advantages including:
         1) A microprocessor controlled pump controller utilizing digital water level sensors.   2) Ability to dynamically adjust the turn on set point of the pump(s) with user actuated push button switches.   3) Eliminates the necessity to enter the sump pit to adjust the float height in order to change the turn on point of the pump(s).   4) Ability to monitor the exact height of the fluid level in the sump pit to within 0.1 inches accuracy.   5) Ability to measure pump current while pump is running and determine whether the pump is operating correctly.   6) Ability to monitor fluid level trending over a specified period to determine whether a pump is operating correctly.   7) Ability to switch power to the pumps using a combination of solid state switch components and mechanical relay components to prolong switch life and increase switching reliably.   8) Ability to determine internal component failures in the power switching component using current sensing methods together with software control algorithms.   9) Ability to determine whether digital level sensors are working properly through the creation and use of dedicated software control programs.   10) Ability to maintain sequenced duplex pump control operation with only one operating digital level sensor.   11) Ability to notify the user of the various alarm conditions through the means of a liquid crystal display.   12) Ability to notify the user of various alarm conditions through the use of the piezo tone generating alarm unit.       

     From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims.