Abstract:
A pump and alarm control promotes water safety and prevents entrapment in swimming pools, spas, and water features, such as fountains and waterfalls. The pump and alarm control monitors the vacuum on the influent side of a pump for the pool, spa and/or water feature and a two speed pump for a spa and automatically detects blockages in the pool, spa and/or water feature drains. The pump and alarm control is capable of detecting entrapment and blockages in different and distinct normal pressure operating conditions. Upon detecting a blockage the pump and alarm control shuts down pump operations and activates audible and visual alarms.

Description:
BACKGROUND OF THE INVENTION 
     Swimming pools and water features can be hazardous to users because of high suction in drains. Blockage of pump return lines can drop the vacuum level, causing the pump and motor to operate at high speeds which leads to their destruction. Existing patents and devices by the inventor, which are incorporated herein by reference, detect when there is a blockage in suction lines or return lines in spas and swimming pools. Different devices are required for distinct normal operating conditions which occur when the pumps are used for circulating and when the pumps are used for increased flows like those that are used in spas and various water features such as fountains and waterfalls. Needs exist for an improved pump and alarm controls that detect blockages and entrapment conditions for pools, spas, and a variety of water features under a variety of operating conditions and shuts down pump operations and sounds an alarm for safety when they occur. 
     SUMMARY OF THE INVENTION 
     A recreational water pump and alarm controller has an interrupter in a pump power circuit for interrupting the pump power circuit and stopping a pump. The controller has a contactor in an alarm control circuit for closing and powering alarms. A vacuum line is connected to a pump suction, and a vacuum sensor is connected to the vacuum line. A vacuum sensor may be mounted on the pump and a vacuum indicating line connected to the sensor and the controller for sending signals of vacuum from the pump to the controller. A vacuum level control is connected to the vacuum sensor for setting plural normal operating pump vacuum levels and plural high and low vacuum levels associated with the plural normal operating pump vacuum levels. The vacuum level controller is capable of automatically setting plural normal and high vacuum levels according to the input of plural pump and/or water operating conditions. 
     A vacuum switch is connected to the vacuum level control and the vacuum sensor and to the contactor and the interrupter for opening the interrupter and closing the contactor upon vacuum in the vacuum line exceeding high or low set vacuum. The apparatus also has a controller input for changing the high vacuum levels according to changed selected pump and/or water operating conditions. 
     In one embodiment a pump is connected to a spa and a two speed motor is connected to the pump. The pump power circuit has a remote motor speed selector for selecting between low speed operation of the motor and pump in a water circulating condition and high speed operation of the motor and pump in a water jetting condition. The controller input is changed and the vacuum level control is changed upon changing of the remote motor speed selector between low speed and high speed operations of the motor and pump. 
     Another embodiment provides the new controller with a swimming pool and spa combination. A pump has a motor connected to the pump power circuit. Water suction lines and return lines are connected to the pump and to the swimming pool and the spa. Valves change connections in the water suction lines and return lines for selective connection of the pump to the swimming pool and the spa for water circulation, and for isolating the pool and connecting the suction and return lines solely between the pump and the spa for jetting water in the spa. The controller vacuum levels are changed upon the changing of the valves to selectively connect the pump to the swimming pool and the spa or solely to the spa. Alternately, the invention may be configured exactly this way but with a water feature in place of or in addition to the spa. 
     The invention also provides a shut off and alarm controller for a swimming pool, spa and water feature such as a fountain, and a waterfall. A pump motor is connected to the pump power circuit. Suction and return lines are connected to the pump and to the swimming pool and the fountain, water feature, or waterfall. Valves in the suction and return lines change the water operating conditions and direct return from the pump to the swimming pool or to the spa or water feature such as a fountain. A connection between the valves or valve operators and the controller input changes the input to the controller when the valves are changed. The invention is configured similarly for use with a waterfall in place of the fountain. 
     The new flow blockage detection, shut off and alarm controller uses a pump vacuum sensor and provides pump stopping and alarm starting in different operating conditions. A first pump operating condition is input into the controller and the pump is started and operated in that condition. The pump vacuum sensor measures the first normal pump vacuum level, which is then set in the pump controller and pump vacuum sensor. Then the pump is stopped. 
     A second pump operating condition is then input into the controller, and the pump is started and operated in that condition. The pump vacuum sensor measures the second normal pump vacuum level, which is then set in the pump controller and pump vacuum sensor. The pump is then stopped. 
     A first operating condition is selected and input into the controller, and the pump is started. The pump vacuum sensor measures the operating pump vacuum level, which is then compared with the first normal pump vacuum level. If the sensed operating pump vacuum level exceeds the first normal pump vacuum level by a preset amount, the pump is stopped and the alarm is started. 
     The pump is stopped, a second operating condition is selected and input into the controller, and the pump is started. The pump vacuum sensor measures the operating pump vacuum level, which is then compared with the second normal pump vacuum level. If the sensed operating pump vacuum level exceeds the second normal pump vacuum level by a preset amount, the pump is stopped and the alarm is started. 
     In one embodiment of the method, the first operating condition is spa water circulating by low speed operation of a two speed pump, and the second operating condition is spa water jetting by high speed operation of the pump. 
     In another embodiment, the first operating condition is spa and pool water circulating and the second operating condition is spa jetting. To select the operating condition, valves in suction lines and return lines are redirected between the pump and the spa and the pump and the pool. The pump operating condition in the controller is then changed based upon the redirecting of the valves. When the valves are operated by remote actuators, and valve position sensors connected to the valves or actuators transmit the valve positions to the controller for setting the pump operating condition. 
     A new method of controlling pumps and alarms provides a pump vacuum sensor and a controller for shutting off the pump and starting an alarm. In the controller are a changeable water flow condition indicator, a pump motor supply circuit, an alarm control circuit, and a vacuum sensor. In the pump motor supply circuit is an interrupter and in the alarm control circuit is an alarm circuit completer. 
     A vacuum line is connected to the controller and to a suction of the pump. The vacuum line may be a fluid line or wire for conducting signals from a vacuum sensor on the pump, pump trap or on a suction pipe. The vacuum sensor measures vacuum in the vacuum line as suction of the pump. A first condition is input into the controller and the pump is operated in that condition. The vacuum sensor monitors vacuum level and first stabilized operation suction of the pump running in the first condition. First activating high and low vacuum levels are set above and below the first stabilized operation vacuum level. 
     The pump is then stopped, and the pump operating and the condition indicator are changed to the second operating condition. The pump is started, and the pump is operated in the second operating condition. The vacuum sensor measures vacuum level and second stabilized operation vacuum level of the pump running in the second condition. Second control activating high and low vacuum levels are set above and below the second stabilized operation vacuum level. 
     When the pump is run in the first condition, upon sensing vacuum level exceeding the first activating high pressure, the interrupter opens, and the alarm circuit completer closes. When the pump is then run in the second condition, upon sensing vacuum level exceeding the second, different, activating high vacuum level, the interrupter opens and the alarm circuit completer closes. 
     In one embodiment of the method, in the first condition the pump is connected through piping to a swimming pool and spa. In the second condition the pump is disconnected from the swimming pool and connected only to the spa. Valves are connected to the piping for circulating water in the pool and spa in the first condition, and jetting water in the spa in the second condition. The redirecting of the valves changes the condition input in the controller. 
     In another embodiment, the pump is connected through piping to a spa. In the first condition the pump is operated at low speed by a two speed motor for circulating water through the spa, and in the second condition the pump is operated at high speed by the two speed motor for jetting water into the spa. Changing pump speeds changes an input in the controller. 
     A new method of operating a recreational water system uses a water pump and motor and provides a flow blockage detection, pump shut off and alarm control in different operating conditions. A pump vacuum responsive power interrupter and alarm actuator are connected to the controller and motor for shutting off the pump and starting alarms in selected water system operations. A resettable condition input, vacuum sensor, and multiple vacuum memory are connected in the system. 
     A discharge side of the pump is connected to a return line. A suction side of the pump is connected to a suction line. A vacuum line is connected to the suction side of the pump and to the vacuum sensor in the safety vacuum release and alarm actuator system. A system control input is connected to the pump power interrupter and alarm actuator system and to the pump and water system controller. The condition input is placed in a first configuration. The pump and motor are operated and the vacuum sensor detects first normal operation vacuum level in a first condition. In the system memory, vacuum level first parameters are set. These parameters are not to be exceeded when operating in the first condition. 
     The pump is then stopped and the condition input is placed in a second configuration. The pump and motor are operated and the vacuum sensor detects second normal operation vacuum level in a second condition. In the system memory, second vacuum level parameters are set. These parameters are not to be exceeded when operating in the second condition. 
     The system control input is set in one condition and the pump is started. After allowing the pump to prime, when a set vacuum level parameter for that operating condition is exceeded, the pump is stopped and the alarms are actuated. 
     The method provides a control relay connected to the system as the system control input. The state of the control relay can be changed from the remote pump control or from valves in the water system. In one embodiment, the first operating condition uses a pump at low speed for circulating water in a spa, and the second condition uses the pump at high speed for jetting water in a spa. In another embodiment the first condition is circulating water through a pool, spa, and/or water feature. The second condition redirects the valves for returning water through the spa and/or water feature. 
     These and further and other objects and features of the invention are apparent in the disclosure, which includes the above and ongoing written specification, with the claims and the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1-7  show pump inlet vacuum measurements in inches of Hg respectively for pool, spa, fountain, waterfall, high normal, low normal and maintenance. 
         FIG. 8  shows a switch face plate with a relay position for pump and water system condition. 
         FIGS. 9 and 10  show relay wiring connections, including a position for pump and water system condition. 
         FIG. 11  is a detail of the relay connections including a connection for pump and water system condition. 
         FIG. 12  shows a preferred connection of the vacuum line. 
         FIG. 13  schematically shows a high and low speed spa system. 
         FIGS. 14 and 15  schematically show a manual pool and spa system changing. 
         FIGS. 16 and 17  schematically show a remote operation pool and spa system changing. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to  FIGS. 1-7  which show pump suction or vacuum in inches of mercury in diagrams  10 , similar numbers are used for similar parts of the diagrams. 
       FIG. 1  shows a pump vacuum-time diagram  1  when a pump is circulating water through a pool. 
       FIG. 2  shows a pump vacuum-time diagram  2  when a pump is jetting water in a spa. 
       FIG. 3  shows a pump vacuum-time diagram  4  when a pump is pumping water through a fountain or similar water feature. 
       FIG. 4  shows a pump vacuum-time diagram  6  when the pump is pumping water through a waterfall. 
       FIG. 5  shows a pump vacuum-time diagram  8  when a pump is operating at a high pressure, such as pumping water through a spa, fountain, waterfall or other water feature. 
       FIG. 6  shows a pump vacuum-time diagram  12  when the pump is operating at a low pressure, such as circulating water through a pool or through a pool and spa. 
       FIG. 7  shows a pump vacuum-time diagram  14  when the pump is being used for maintenance of a pool, spa or water feature. 
     In all of the diagrams  10 , the Y direction  3  indicates the pump vacuum and the X direction  5  indicates time. When the pump is switched on  7 , the pump vacuum begins to rise  9  and continues to rise to its peak  11 , and after the starting time  13  when the pump is fully primed, the pump vacuum returns to normal  15 . Normal positive and negative pump vacuum spikes  16  occur during normal operations of the pool pump. Preset controller activating levels of an increase in pump vacuum  17  or a decrease in pump vacuum  19  from the normal operating pump vacuum level  15  in the selected operating condition indicate the outer limits of normal vacuum levels. When a blockage occurs  21 , pump vacuum spikes  23  beyond the normal preset positive increase in pump vacuum  17 . At a point  22  where the pump vacuum exceeds the normal preset positive increase in pump vacuum  17 , power to the pump is shut off and alarms are activated. 
     The pump vacuum immediately falls  25  to a zero point. The time between shutting off the pump as the pump vacuum level crosses  22  the preset normal high fluctuation  17  until the pump vacuum falls to zero is the response time  28 . 
     For the start time  13  while the pump primes and pump prime vacuum peaks  11 , the pump shutoff and alarm system are deactivated. 
     Reactivating the system after shutoff at point  22  requires investigating and removing the cause of shutoff and inspecting the pool. 
     In the spa pump vacuum-time diagram  2  shown in  FIG. 2  the curves are similar, with the exception that the normal operating pressure  15  of the spa is higher than the normal operating pressure of the pool circulating pump, and the high and low ranges  17  and  19  are set at higher vacuum levels. 
     For the fountain pump vacuum  4  shown in  FIG. 3 , the curves are the same, with the exception that the pump output pressure is higher for fountain operation, and that the pump vacuum for normal fountain operation  15  is different from the normal pool circulation vacuum  15  in  FIG. 1 . The normal high and low vacuum limits  17  and  19  are changed accordingly. If one of the levels  17  or  19  is exceeded, as shown for example in curve  23 , the pump is shut off and the alarms are started. 
     In a waterfall operation  6 , such as shown in  FIG. 4 , the pump usually is operating at a higher pressure because of the necessity to lift the large volume of water to the waterfall. Because the normal pump vacuum  15  is different than in normal pool operation, the limits  17  and  19  differing from that normal vacuum are changed accordingly. The pump is shut off and the alarms are sounded when the vacuum exceeds either preset limit  17  or  19 . 
     A pump operates in two different modes, for example circulating water in a pool and spa in one mode and stopping the circulation through the pool and jetting water in the spa in another mode. 
       FIG. 5  shows a high normal pump vacuum operation in which the high normal level  15  has upper and lower high normal limits  17  and  19  by which the pump turns off and the alarms activate upon exceeding the upper or lower  17 ,  19 . 
       FIG. 6  shows a low normal operation  12  in which the pump operates at a low normal vacuum level  15  and the upper and lower limits  17  and  19  are set accordingly. 
     In all of the operations shown in  FIGS. 1-6 , the pump shutoff and alarm activation is deactivated during the start time  13  until the pump primes. After the start time, the systems respond to any exceeding of the upper and low limits  17  and  19  by turning off the pump and activating the alarms. 
     During the maintenance cycle  14 , as shown in  FIG. 7 , the vacuum-time diagram  30  is different from the vacuum-time diagrams  10  shown in  FIGS. 1-6 . After the maintenance condition is selected and the pump is switched on, the pump vacuum increases until it reaches the highest vacuum  31  during the pump prime. At the end of the start time  33 , the pump is primed and the pump operates at the normal pump maintenance vacuum level  35 . Relatively high maintenance vacuum spikes  36  occur during maintenance vacuuming of the pool. Consequently the positive increase in pump vacuum requires a higher normal vacuum range setting  37 . The low range  39  may also be set farther away from the normal maintenance operating vacuum  35 . 
     The pump shutoff and alarm control  50  has a face plate  51  with a clear window  53 , with alphanumeric display. Off/stop switch  55  immediately stops pump operation and also silences any active alarms. On/run switch button  57  toggles between timed pump run, continuous pump run and remote control modes and spa mode, as indicated in the alphanumeric display  53 . Maintenance/clean push button  59  initiates the maintenance/cleaning mode of the pump and allows the pump to operate continuously for thirty minutes in the maintenance/cleaning mode. During the maintenance/cleaning mode, vacuum is not monitored, and a blockage will go undetected during the thirty minute cycle. An alarm is activated continuously while the pump is operating in maintenance mode. 
     The assembly of buttons  60  is used to set up modes for time, date and pump operating schedule, to set normal operating vacuum levels for different pump operating modes, and to set ranges around the operating levels which are detected during setup operations. The set button  61  selects the mode, and the +/yes button  63  and the −/no button  65  are used to answer yes or no questions and to increment or decrement the value on the display  53 , for example in date and time, operating schedule and pump vacuum level and upper and lower vacuum range during selection. 
     The lower part of the face plate shows the appropriate locations for the vacuum sensor hose connection  67 , the control wiring  68 , and the power wiring  69 . 
     The actual connectors are schematically shown  70  in  FIG. 11 . Two terminals are connected to the remote switch in  71  for inputting on and off signals from remote controls. The heater delay  72  provides a control signal to a heater at the pool. 
     Remote alarm contactors  73  provide low voltage output power to remote alarms. Mode selection in connectors  74  input the mode selected by remote control, such as by the changing of valves to direct water flow between pump and spa circulation and spa jetting, or selected pump speed for two-speed operation between spa circulating and spa jetting. Heavy duty connectors  75  connect the main power lines through heavy duty relays to connect input power lines to line  1  and line  2  connectors  76  and  77  and output power lines to the pump to load  1  connector  78  and load  2  connector  79 . 
       FIGS. 9 and 10  show the wiring between the pump and the feed, and the vacuum hose connection to the control. 
       FIG. 12  shows preferred vacuum line connections between the pump  90  and the controller  50 . The preferred connection of the vacuum line  91  to the pump is at the sensor or coupling  93  of the lint trap  95 . Water from the main drain comes to the pump through inlet pipe  97  and exits pump  90  through return line  99  to the water jets in a circulating mode or in a water jetting mode in a spa. The vacuum line  91  may be a fluid line or wire for conducting signals from a vacuum sensor on the pump, pump trap, or on a suction pipe. 
     A breaker panel or pump controller  100  provides power through conduit  101  to controller  50 . Relays in the controller  50  connect the power from input  101  appropriately to provide power through conduit  103  to the pump motor  105 . 
     In the control diagram  110  shown in  FIG. 13 , the spa control board  111  is a remote installation which selects by control switches or buttons  113 ,  115  low speed operation of a pump for circulating water in the spa, and high speed operation of pump  90  jetting water through the spa. Controller  150  has power input lines  120  from the SPA control board  111 , which includes a first power line  121 , a common or neutral line  123 , and a ground  125 . Relays  127  and  129  in the control  150  connect the input power lines  120  to output power lines  130  to the pump motor  105 . The power lines between the control box  150  and the pump motor have first and second phase power lines  131  and  132  for running the pump  105  at low and high speeds and common line  133  and ground  135 . The ground lines  125  and  135  are directly connected across the control box. The common line is connected via control relay  127 , and the power lines  121 ,  131 ,  132  are connected by power line relay  129 , depending on the pump speed selected by the spa control board  111 . 
     The controller  150  has low set and high set buttons  151  and  153 . In a setup mode, the low set button  151  is pushed, and pump  90  is started with relay  129  in a low speed condition. Vacuum sensor  92  senses the vacuum on vacuum line  91  after about ten seconds for the pump priming. The sensed vacuum is input into the controller as low speed normal vacuum. Controller  150  automatically selects high and low vacuum levels  17  and  19 , as shown in  FIGS. 1-7 . The automatically selected high and low vacuum levels for stopping the pump and actuating the alarms may be raised or lowered by selecting upper level with the set button and raising or lowered the upper level with buttons  63  or  65 , as shown in  FIG. 8 . The same may be done for the lower level by selecting lower level with the set button and raising or lowering the lower level with buttons  63  or  65 . 
     The differential between the normal operating vacuum experienced during setup and the upper and lower levels is controlled so that the differentials cannot be reduced beyond preset range limitations. 
     When the controller is fully set for the low speed operation, the pump is stopped by pushing off/stop button  55 , as shown in  FIG. 8 . 
     A two speed pump controller  150  is shown in  FIG. 13 . The pump is started, and after about ten seconds the high speed operation vacuum on line  91  is sensed by vacuum sensor  92  in the controller  150  or vacuum sensor or coupling  93  on the pump. High set button  153  is pressed in controller  150 . The vacuum level may be displayed in a window on the control panel  150 . The high normal cutoff level  17  for the high vacuum normal operation may be displayed. The high cutoff level of  17  may be raised or lowered within preset constraints by pushing buttons on the controller  150 . The lower cutoff and alarm level  19  for the high vacuum operation may be displayed. That lower cutoff level  19  may be raised or lowered by pressing buttons on the controller. 
     After blockage has been removed pressing reset/restart button  155  on controller  150  restarts the controller and the pump. 
     The pump is turned off, the high set button  155  is pressed and the above procedure is repeated for the high normal operation levels  15 ,  17  and  19 , as shown in  FIG. 5 . 
     The system uses printer circuit board layout  156  with components to transform and rectify the power, control main pump power relays and to control low voltage alarm relays and heater delay relays while accepting inputs from remote pool, spa and water feature controls. A green LED  157  indicates that the system is operating. A high vacuum alarm LED  158  indicates a blockage, and a low vacuum alarm is a red LED  159  which indicates a shutoff and alarm activation from low vacuum level. In one embodiment, if both LED&#39;s  158  and  159  are illuminated, that will indicate that the pump has been shut off by a blockage and high vacuum. If only LED  159  is illuminated, that indicates that the pump has been shut off and an alarm has been activated by a low vacuum at the pump intake. 
       FIG. 14  shows changing a pool and circulating mode to a spa mode with the pump shut off. The system is shut off  160 , and the valves are changed manually  162 . Changing the valves manually  162  may signal the remote input  74  of the selection  164  of the spa mode. Normally the valves are manually changed, and the On button  57  is pushed four times  166 , toggling the display through continuous, timed, and remote modes to the spa mode, which starts the spa in the high parameter. The system runs in the spa mode until the system is turned off  169  at the remote. The control system is in the off condition  170 . The valves are changed  172  to the pool and spa circulating position. Pushing the On button once  176  starts the system in continuous circulating mode. The system continues to run until the system is turned off  178  by the controller. 
     In changing a manually operated system, as shown in  FIG. 14 , the goal of the switch is to isolate the pool from the filtration system so that only the water in the spa is heated and circulated. In many cases, the user will need to switch a three-way valve on the suction side from pool to spa, and accordingly switch a return three-way from both open to spa only. Alternatively, the user will open a ball valve for the spa and shut a ball valve for the pool on the suction side, and shut a ball valve for pool return flow on the return side. Either can be accomplished in under forty-five seconds, but a timer should not be needed in a manually operated case. 
     In  FIG. 15 , the unit is running in a timed pool and spa circulating mode  180 . The remote control turns the system off  182 . While the system is off  160 , the valves are manually changed  162 . Changing the valves manually  162  may signal the remote input  74  of the selection  164  of the spa mode. Normally the valves are manually changed, and the On button  57  is pushed four times  166 , toggling the display through continuous, timed, and remote modes to the spa mode, which starts the spa in the high parameter. The system runs in the spa mode until the system is turned off  169  at the remote. The control system is in the off condition  170 . The valves are changed  172  to the pool and spa circulating position. Pushing the On button once  176  starts the system in continuous circulating mode. As soon as the remote turns the system back on  176 , the timed circulation  180  continues. 
       FIGS. 16 and 17  schematically show a remote operation pool and spa system changing. 
     As shown in  FIGS. 16 and 17 , valve changes on an automated system are handled by motorized actuators commanded by a remote keypad. Pump operations are already handled by the remote switch input. When the auto-system calls for the pump, it is turned on by the controller operating in remote mode. The valve change triggers the mode change in the controller in the same fashion, via a dry contact provided by an additional relay wired to the actuator relay. In an automated valve change, the only user interface is a button push on a remote keypad. That stops the pump and sends a 24 v signal to valve actuators, causing them to move to their preset positions for spa use. The actuators are preset with two stop points, and simply switch back and forth between the two points. The system then restarts the pump. In most cases the heater will be fired in a spa setting, and additional components such as air blower may be actuated. Pushing a button on the remote keypad to return to pool mode reverses the process. 
     As shown in  FIG. 16 , the remote operation of the system uses a remote control to first turn the pump off  190 . The valves change to a spa mode via a pool/spa valve actuation circuit. The system changes to a spa mode  194  with the control levels in high normal condition, as shown in  FIG. 5 . The controller enables the pump to be started in the spa mode  196 , and the remote  198  starts the pump through a signal to the controller. To return back to the pool and spa circulating mode via the remote panel  200 , the remote unit stops the pump  202  and the automatic valve change  204  sends a signal to the controller to change to the circulating mode. The remote remains off  206  until it is intentionally activated. 
     As shown in  FIG. 17  in the remote controlled operation, the system is on and the pump is on  210 . The spa mode  212  is selected by the remote panel. The remote unit automatically stops the pump  190 , and the valve change enables the spa mode  192  in the controller. The remote unit restarts the pump  198 , and the system operates in the spa mode  214 . When the pool mode is chosen by the remote panel  200 , the remote unit stops the pump  202 , the valve change disables the spa mode  204 , and the remote unit restarts the pump  216  and the pump continues to operate  218  in the pump circulating mode. 
     While the invention has been described with reference to specific embodiments, modifications and variations of the invention may be constructed without departing from the scope of the invention, which is defined in the following claims.