Patent Publication Number: US-10323633-B2

Title: Pump control system having emergency run mode

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of the filing date of U.S. Provisional Application Ser. No. 61/863,138 filed Aug. 7, 2013, entitled, “Pump Control System Having Emergency Run Mode”. The &#39;138 application is hereby incorporated herein by reference. 
    
    
     FIELD 
     The application pertains to control systems which sense water levels at a predetermined location and activate one or more pumps. More particularly, the application pertains to such control systems wherein, in response to sensed trouble conditions, duplex pumping or pump specific simplex operation is restricted based on past and present current draw. 
     BACKGROUND 
     Systems are known to sense water levels at predetermined locations, and in response thereto, activate one or more pumps to control the water level. In this regard, one or two pumps can be activated. While useful, known systems can suffer from sensor or motor failures which can produce an undesirable flood condition. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a system configuration in accordance herewith; 
         FIG. 2  illustrates a block diagram of a controller in accordance herewith; 
         FIG. 3  is a flow chart illustrating an operational method in accordance herewith; and 
         FIG. 4  is a flow chart illustrating another operational method in accordance herewith. 
     
    
    
     DETAILED DESCRIPTION 
     While disclosed embodiments 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 thereof as well as the best mode of practicing same, and is not intended to limit the application or claims to the specific embodiment illustrated. 
     A pump controller in accordance herewith senses a water level of up to a predetermined depth. To control or reduce the water level, embodiments hereof include a configurable water level/pump turn-on setting, the ability to run two pumps simultaneously, pump alternation, pump failure sensing, local audible/visual alarm notification, local alarm silencing, and remote alarm notification. Locations of use include sumps in residential or commercial buildings without limitation. 
     In one embodiment, an Ethernet module can provide a web page interface that displays system information and alarm notification remotely via email and text messages. Local outputs at the controller can include a display of local conditions, an LED-type display, as well as an audio alarm or a contact closure to provide immediate, and direct feedback to a user. 
     First and second water sensors can be coupled to the controller. A lower sensor is intended to be installed at a lower or bottom water level. In normal operation, that sensor will cause a running pump to turn off when the water level is low enough. The same sensor can cause the pump to turn on when the water level increases to a preset level. The second sensor is intended to be installed at a location higher than the first sensor, relative to the water level, to provide a high water alarm level. 
     Embodiments hereof can operate in several different operating modes with one or two pumps. In a duplex alternating mode, the controller will run one or two pumps simultaneously in response to local water conditions. In a simplex alternating operating mode, two pumps are available but they will not be energized simultaneously. 
     Under any of the following conditions, the controller will enter a state of alarm. These include, detection of a pump failure, the water level reaching the second or high level sensor, or a failure of a lower water level sensor. Additionally where a pump has been continuously running but the water level remains above the lower level sensor for a predetermined period of time, embodiments hereof will enter the alarm state. 
     Once in an alarm state, the controller can notify the user that there may be trouble by initiating audible and visual cues, breaking (electrically opening) the remote alarm contacts which can be connected to another alarming device, allowing it to inform the user remotely (these contacts are normally closed). Additionally, the controller can communicate the alarm to an optional internal alarm module, or externally via wireless communications for further handling. 
     If the first, or lower level sensor (DLS) connected to the controller is disconnected, faulted, or has otherwise failed while the controller is operating with the second, higher level, sensor installed the controller enters an “Emergency Run”, or SOS, mode. In this mode, once the higher level sensor (HLS) reads a water level&gt;=a min_threshold for a certain period of time, the controller then will begin the process of starting all available pumps one at a time with minimum time delays between starts. 
     Pump(s) will remain energized until the high level sensor reads a water level&lt;an off threshold for predetermined period of time. Then the pump(s) will be turned off one at a time with minimum time delay in between off intervals. If two pumps are available and not previously locked out by the current protection processing, duty cycle alternation will occur once the lead pump (first pump started) turns off. 
     Since the characteristics of a wide variety of pumps, pit depths and pump sizes need to be addressed and cannot be predicted, if the lower level sensor has failed, the controller has no lower water level off signal. Hence, in accordance with embodiments hereof, an emergency run mode is provided which causes pumping to occur at user defined time intervals once the second, or higher level sensor has been activated. 
     In another aspect, if both water, or fluid, sensors connected to the controller are disconnected, faulted, or otherwise fail, the controller enters an “SOS” mode where an available pump is run for a predetermined time period and then turned off for different time period. If two pumps are installed and not previously locked out by the current protection processing, the controller will alternate pumps based upon a predetermined duty cycle. 
     For example, the controller&#39;s “SOS” mode can set to run a pump for thirty seconds and then turn it off for ninety seconds. If two pumps are installed and available: pump1 can be set to run for thirty seconds, then pump1 will turn off. After ninety seconds pump2 can start and run for thirty seconds, then pump2 will turn off. After ninety seconds pump1 starts and the cycle repeats indefinitely. 
     In yet another aspect, the present method maintains some level of pumping operation while minimizing possible adverse effects on the pumps (due to pumping dry) when the controller has lost all sensors and is “flying blind” in terms of level based control. In embodiment&#39;s hereof, the “SOS” mode pumps and attempts to avoid flooding while trying to keep wear and tear on the pumps to a minimum. 
       FIGS. 1, 2  illustrate aspects of a system  10  in accordance herewith. The system  10 , discussed below, can implement some or all of the aspects discussed above. As those of skill will understand, variations of the above described processing come within the spirit and scope hereof. 
     System  10  includes a controller  14  which can be coupled by cables to a lower sensor  16 , a high water alarm level sensor  18 , and two pumps,  20 ,  20 . Pumps can have AC or DC motors without limitation. In  FIG. 1 , the level sensors  16 ,  18  and pumps  20 ,  22  are illustrated installed in a sump S in which water collects. 
     Controller  14  carries in housing  14 - 1  control circuits  30  which can be implemented in part with one or more processors  30   a  and associated, executable, control software  30   b . The control circuits  30  are coupled to AC/DC switching element  32  which can selectively, in response to control circuits  30  deliver AC/DC electrical energy to one or both of pumps  20 ,  22 . 
     Control circuits  30  are also coupled to incoming signals from sensors  16 ,  18  as well as pump motor current sensor  34 . Output devices display  36   a , audio alarm  36   b , contact closure  36   c , as well as wireless interface  38  provide communications to users locally or displaced from the controller  14 . The interface  38  can communicate wirelessly via wireless medium W, and a computer network, such as the internet I with a user&#39;s wireless phone, tablet or computer  40  to provide updates as well as receive instructions for settings of the control circuits  30 . 
       FIGS. 3,4  illustrate aspects of processing by controller  14 , without limitation. Process  100 , of  FIG. 3 , illustrates operation in response to detecting that either the first or second sensors, DLS, or HLS have exhibited disconnection, failure or faulting, as at  102 . In response thereto, controller  14  enters the SOS operational mode as at  104 . Available pump(s) are started as at  106 . 
     A determination is made as to the number of available pumps, as at  108 . The number of available pumps can be continually checked by controller  14  using the pump motor current sensor  34 . 
     If a single pump is available, it is operated in a simplex non-alternating mode, as at  110 . Where two pumps are available, they are operated in a simplex alternating mode. The lead pump is energized for a predetermined “on” time, for example, thirty seconds, as at  112 . Subsequent to the “on” time, the operating pump is turned off, and the pumps are alternated so that the other one becomes the lead pump in the next cycle. An “off” timer is then started, for example 90 seconds, as at  116 , and the process returns to  112  for the next cycle. 
     In both of the above modes of  FIG. 3 , the energized pump has the full outlet current available since only one pump at a time is activated. Unlike the above,  FIG. 4  illustrates a duplex alternating pump control process  200 , an emergency run mode, which uses two pumps which can be simultaneously run using available current from the electrical outlet to which controller  14  is connected. Alternately, a separate feed can be provided to energize the pumps without departing from the spirit and scope hereof. 
     Process  200  is executed where the controller  14  determines that the lower sensor  16 , DLS is disconnected, has failed or faulted, as at  202 . Where the high level sensor  18 , HLS, provides a signal of a high water alarm level, as at  204 , a delay is started, for example thirty seconds, as at  206 . Subsequent to the delay the lead pump, one of  20 ,  22 , is energized, as at  208 . 
     Where two pumps are available, a second delay can initiated as at  210 . Subsequently the lag pump, the other of  20 ,  22 , can be energized as at  212 . At this time, both pumps are running. 
     Both pumps continue to run until the high level sensor  18  signals that the fluid level has fallen to or below the alarm level, as at  214 . Where two pumps are available, a minimum run delay timer is started, as at  216 . Both pumps continue to run during this delay time. 
     Subsequently, at  218  the lag pump is turned off, while the lead pump continues to run. After a further delay, as at  220 , the second, or lead pump, is turned off as at  222 . The pumps can be alternated as at  224 . The emergency run mode of  FIG. 4  operates to keep the high level water in the sump S in the absence of a low level signal while at the same time avoiding a condition where the pumps are running dry because the sump has been pumped out. Unless the high level sensor sensing the high water alarm level, the process  200  will not be executed. 
     In addition to sensing and evaluating signals from the two level sensors,  16 ,  18  the controller  14  can detect pump motor failures. Pump motor condition can be evaluated by circuits  30  using the motor current sensor  34 . Whenever a pump draws an abnormal current, the controller can detect it and then in response thereto enter an alarm state indicating to the user that pump servic  4  is needed. 
     The following three Tables illustrate these conditions for various modes of operation as discussed above. An “X” in a column indicates that an action or state has occurred at the respective entry. 
     Table 1 illustrates aspects of duplex operation, process  200 , where both pumps  20 ,  22  are intended to run simultaneously when required. Table 2 illustrates aspects of alternating simplex operation as illustrated in process  100  where two pumps  20 ,  22  are present. Table 3 illustrates aspects of non-alternating simplex operation with only one installed pump. 
     
       
         
           
               
             
               
                 TABLE 1 
               
             
            
               
                   
               
               
                 Duplex Operation-2 pumps installed; both intended to run simultaneously when required. 
               
            
           
           
               
               
               
               
               
               
               
               
               
               
            
               
                   
                   
                 Duplex 
                 Duplex 
                   
                   
                   
                   
                 Open 
                   
               
            
           
           
               
               
               
               
               
               
               
               
               
            
               
                 Number 
                   
                 Pumping 
                 Pumping 
                 Pump 
                 Alternate 
                   
                 Remote 
                   
               
            
           
           
               
               
               
               
               
               
               
               
               
               
            
               
                 of Pumps 
                   
                 Locked 
                 Forced 
                 Locked 
                   
                 To Next 
                   
                 Alarm 
                 LCD 
               
               
                 Running 
                 Current 
                 Out* 
                 Off †   
                 Out 
                 Bad ‡   
                 Pump 
                 Beep 
                 Contacts 
                 Updates 
               
               
                   
               
               
                 2 
                 Extreme 
                 X 
                 X 
                   
                   
                   
                 X 
                 X 
                 X 
               
               
                   
                 High, 3 Times 
                 X 
                 X 
                   
                   
                   
                 X 
                 X 
                 X 
               
               
                   
                 High 
                   
                 X 
                   
                   
                   
                   
                 X 
                 X 
               
               
                   
                 Low 
                   
                   
                   
                   
                   
                 X 
                 X 
                 X 
               
               
                 1 
                 Critical 
                 N/A 
                 N/A 
                 X 
                   
                 X 
                 X 
                 X 
                 X 
               
               
                   
                 Extreme, 3 Times 
                 N/A 
                 N/A 
                   
                 X 
                 X 
                 X 
                 X 
                 X 
               
               
                   
                 Extreme 
                 N/A 
                 N/A 
                   
                   
                 X 
                   
                 X 
                 X 
               
               
                   
                 High, 3 Times 
                 N/A 
                 N/A 
                   
                   
                   
                   
                 X 
                 X 
               
               
                   
                 High 
                 N/A 
                 N/A 
                   
                   
                   
                   
                 X 
                 X 
               
               
                   
                 Low 
                 N/A 
                 N/A 
                   
                   
                 X 
                 X 
                 X 
                 X 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 2 
               
             
            
               
                   
               
               
                 Alternating, Simplex Operation-2 pumps  
               
               
                 installed, only one pump intended to run at one time. 
               
            
           
           
               
               
               
               
               
               
               
               
            
               
                   
                   
                   
                   
                   
                   
                 Open 
                   
               
            
           
           
               
               
               
               
               
               
               
            
               
                 Number 
                   
                 Pump 
                 Alternate 
                   
                 Remote 
                 LCD 
               
            
           
           
               
               
               
               
               
               
               
               
            
               
                 of Pumps 
                   
                 Locked 
                   
                 To Next 
                   
                 Alarm 
                 Up- 
               
               
                 Running 
                 Current 
                 Out* 
                 Bad ‡   
                 Pump 
                 Beep 
                 Contacts 
                 dates 
               
               
                   
               
               
                 1 
                 Extreme 
                 X 
                   
                 X 
                 X 
                 X 
                 X 
               
               
                   
                 High, 3  
                 X 
                   
                 X 
                 X 
                 X 
                 X 
               
               
                   
                 Times 
                   
                   
                   
                   
                   
                   
               
               
                   
                 High 
                   
                 X 
                 X 
                 X 
                 X 
                 X 
               
               
                   
                 Low 
                   
                   
                 X 
                 X 
                 X 
                 X 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 3 
               
             
            
               
                   
               
               
                 Non-Alternating, Simplex Operation-pump 
               
               
                 installed, only pump 1 will run. Pump 2 is disabled. 
               
            
           
           
               
               
               
               
               
               
               
            
               
                 Number 
                   
                   
                   
                   
                   
                 LCD 
               
            
           
           
               
               
               
               
               
               
            
               
                 of Pumps 
                   
                 Pump 
                   
                 Open Remote 
                 Up- 
               
            
           
           
               
               
               
               
               
               
               
            
               
                 Running 
                 Current 
                 Locked Out* 
                 Bad ‡   
                 Beep 
                 Alarm Contacts 
                 dates 
               
               
                   
               
               
                 1 
                 Extreme 
                 X 
                   
                 X 
                 X 
                 X 
               
               
                   
                 High, 3  
                 X 
                   
                 X 
                 X 
                 X 
               
               
                   
                 Times 
                   
                   
                   
                   
                   
               
               
                   
                 High 
                   
                 X 
                 X 
                 X 
                 X 
               
               
                   
                 Low 
                   
                   
                 X 
                 X 
                 X 
               
               
                   
               
               
                 *Duplex Pump Mode or pump is permanently locked out from running until controller is reset. 
               
               
                   † Running two pumps simultaneously is temporarily disabled; that is, one pump is turned off. 
               
               
                   ‡ Pump is only run as a lag (secondary) pump. 
               
            
           
         
       
     
     In summary, as described above, duplex pumping, or pump specific simplex operation is restricted based on past and present current draws to avoid tripping circuit breakers and to keep the pump(s) running as long as possible. As described above, when both the digital level sensor (DLS) and high level sensor (HLS) are disconnected, failed or faulted, the controller enters the SOS mode. The number of pumps available to the controller is subject to the configuration of the controller and associated current protection feature, or processing. 
     The current protection processing continually checks the health of the pump(s). If one or both of the pumps are deemed locked, failed or faulted, the respective pump(s) is/are no longer available to the controller for operation. If either the DLS sensor or the HLS sensor are reconnected, the controller will exit the SOS mode and resume normal operation. 
     From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope hereof. 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. Further, logic flows depicted in the figures do not require the particular order shown, or sequential order, to achieve desirable results. Other steps may be provided, or steps may be eliminated, from the described flows, and other components may be add to, or removed from the described embodiments.