Abstract:
A dual speed pump controller includes a motor controller for operating a dual speed motor. The controller includes an operating speed circuit for operating the motor in one of a first speed or a second speed, the first speed being greater than the second speed; an event circuit for operating the motor at the first speed before a predetermined event and operating the pump at the second speed after the predetermined event.

Description:
PRIORITY 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/903,583, filed Nov. 13, 2013, the entire content of which is incorporated herein by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The present disclosure generally relates to motors operating pumps and pump controllers, systems and methods for controlling pumps in various applications, and more particularly, to a pump having a dual speed pump controller for controlling the operation of recirculating pumps used in swimming pool environments. 
       BACKGROUND 
       [0003]    Standard recirculating pumps are used in swimming pool environments in connection with the filtering systems. The pumps are often high capacity pumps that move thousands of gallons per hour. The electric power required to move these large volumes of water is often very high. Many federal and local governments have enacted laws and regulations to curtail this high electric use. 
         [0004]    Attempts that have been made to design pumps within the legally required specifications include for example timers, voltage controllers, and flow volume modifications, none of which adequately address the problem at hand. 
         [0005]    This disclosure describes improvements over these prior art technologies. 
       SUMMARY 
       [0006]    Accordingly, a motor controller connected to a pump is provided. The dual speed pump controller includes a motor controller for operating a dual speed motor, comprising: an operating speed circuit for operating the motor in one of a first speed or a second speed, the first speed being greater than the second speed; an event circuit for operating the motor at the first speed before a predetermined event and operating the pump at the second speed after the predetermined event. 
         [0007]    Accordingly a method for operating a motor connected to a pump and a controller is provided. The method includes operating the motor by the controller at a first speed for a predetermined amount of time; and after the expiration of the predetermined amount of time, switching by the controller the speed of the motor to a second speed, wherein the first speed is greater than the second speed. 
         [0008]    Accordingly a method for operating a motor connected to a pump and a controller is provided. The method includes operating by the controller the pump at a first speed; receiving at the controller pressure data from a pressure sensor indicating an output pressure of the pump; if the output pressure is below a predetermined pressure, continuing the operation of the pump at first speed; and if the output pressure is above a predetermined pressure, operating the pump at second speed, wherein the first speed is greater than the second speed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The present disclosure will become more readily apparent from the specific description accompanied by the attached drawings, in which: 
           [0010]      FIG. 1  is a block diagram illustrating a controller for controlling a dual speed pump according to the present disclosure; and 
           [0011]      FIG. 2  is a flow diagram illustrating a method for controlling a dual speed pump according to the present disclosure. 
       
    
    
       [0012]    Like reference numerals indicate similar parts throughout the figures. 
       DETAILED DESCRIPTION 
       [0013]    The present disclosure may be understood more readily by reference to the following detailed description of the disclosure taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this disclosure is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed disclosure. 
         [0014]    Also, as used in the specification and including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It is also understood that all spatial references, such as, for example, horizontal, vertical, top, upper, lower, bottom, left and right, are for illustrative purposes only and can be varied within the scope of the disclosure. 
         [0015]    Reference will now be made in detail to the exemplary embodiments of the present disclosure, which are illustrated in the accompanying figures. 
         [0016]      FIG. 1  is a block diagram illustrating an embodiment of a dual speed pump controlled according to the present disclosure. Controller  100  consists of control circuitry  10 , input device  20  and relay  30 . In other embodiments, controller  100  can also include indicator(s)  40 . Controller  100  is connected to a dual speed motor  60  which in turn is connected to pump  70 . Input line voltage is routed via relay  30  to either the low speed or high speed connections of motor  60 . In other embodiments, pressure sensor  50  can be connected to pump  70  and control circuitry  10  to provide pressure data from pump  70  to controller  100 . 
         [0017]    Control circuitry  10  is designed to implement the method for operating the controller and switch the pump motor  60  between its low speed and high speed. Control circuitry  10  can be electronic circuitry designed or a microprocessor programmed to switch relay  30  based on the method of control described herein. 
         [0018]    Input device  10  is available to select between different modes of operation, including a normal operating mode and a service operating mode. In addition, input device  10  is available to select between different voltage input levels, if available, e.g. 120 V or 240 V. Input device  10  can be implemented as one or more switches, including, but not limited to, dip switches, slide switches, push button switches and/or toggle switches. 
         [0019]    Indicator(s)  40  can include lights and/or display devices to indicate the settings of the controller  100 , e.g. normal operating mode at high speed or service mode at low speed. For example, indicator(s)  40  can include light emitting diodes (LEDs), incandescent bulbs, digital displays, etc. 
         [0020]    For priming, pressure sensor(s)  50  can be included to sense an output pressure of pump  70  when priming is complete and automatically switch to a lower speed. Pressure sensor(s)  50  can include pump outlet water taps or electronic devices to sense when priming is complete. 
         [0021]    Motor  60  can be any motor manufactured to operate at more than one speed. Although motor  60  is described herein as having an internal configuration to operate at various speeds, an external speed controller is contemplated and would be controlled by controller  100 . Motor  60  can include low speed, high speed and service settings. The use of differing speeds can reduce the total power consumption to 1/8  the power consumption of uncontrolled use. 
         [0022]    Pump  70  can be any mechanical pump for moving liquids. The present disclosure discusses swimming pool applications, but the present disclosure is not limited thereto. 
         [0023]    In operation, the controller  100  is an electronic switch assembly which controls the input motor  60  to operate in an automatic mode, an off mode or a service mode. In the automatic mode, motor  60  is operated at a high speed until the occurrence of an event and is then switched to a low speed mode. The event could be a the end of a specific time limit (e.g. 5 minutes, 10 minutes, etc) or the reaching of a threshold pressure sensed by pressure sensor  50  at the output of the pump  70  that signifies the pump is primed; other events are contemplated. In the service mode motor  60  is permitted to run for a longer period of time (e.g. 3 hours) if high speed service mode is selected and is then switched back to low speed mode after the expiration of the time. Motor  60  will continue to run in low speed until power is interrupted. 
         [0024]      FIG. 2  is a flow diagram illustrating a method for controlling a dual speed pump according to the present disclosure. 
         [0025]    In step s 1 , control circuitry  10  determines if the process should begin normal operation. This determination is made based on the input of a user using the input(s)  20 . If normal operation is selected, the process continued to step s 2 , else the process continues to step s 7 . In step s 2 , controller  100  operates motor  60  at a high speed. In step s 3 , control circuitry  10  determines if the predetermined event has occurred. If so, the process continues to step s 4 , else the process returns to step s 3 . It is noted that the event can be, for example, the expiration of a timer or the reaching of a pump output pressure. In step s 4 , if the event has occurred, controller  100  operates motor  60  at a low speed. In step s 5 , if controller  100  is instructed to switch off the power, the power is switched off in step s 6 , else the process returns to step s 1 . 
         [0026]    If normal operation is not selected in step s 1 , in step s 7  process enters the service mode. In step s 8 , the control circuitry  10  determines if a high speed is selected based on the input of a user via input  20 , and if selected proceeds to step  9 , else to step a 11 . In step s 9 , if a high speed is selected, controller  100  operates motor  60  at a high speed. In step s 10 , control circuitry  10  determines if the service mode timer has expired. If not, the process returns to step s 10 . If the service mode timer has expired in step s 10  or if the high speed is not selected in step s 8 , in step s 11 , controller  100  operates motor  60  in a low speed. 
         [0027]    The present disclosure has been described herein in connection with a pump in a swimming pool environment. Other applications are contemplated. 
         [0028]    Where this application has listed the steps of a method or procedure in a specific order, it may be possible, or even expedient in certain circumstances, to change the order in which some steps are performed, and it is intended that the particular steps of the method or procedure claim set forth herebelow not be construed as being order-specific unless such order specificity is expressly stated in the claim. 
         [0029]    While the preferred embodiments of the devices and methods have been described in reference to the environment in which they were developed, they are merely illustrative of the principles of the inventions. Modification or combinations of the above-described assemblies, other embodiments, configurations, and methods for carrying out the invention, and variations of aspects of the invention that are obvious to those of skill in the art are intended to be within the scope of the claims.