U.S. patent application number 11/590242 was filed with the patent office on 2007-04-26 for method and system for testing spas.
Invention is credited to Jeffrey A. Buchman, James L. Tarpo.
Application Number | 20070093920 11/590242 |
Document ID | / |
Family ID | 35055477 |
Filed Date | 2007-04-26 |
United States Patent
Application |
20070093920 |
Kind Code |
A1 |
Tarpo; James L. ; et
al. |
April 26, 2007 |
Method and system for testing spas
Abstract
A test system and method for testing a spa system which includes
a spa tub for holding water, an electronic controller system which
controls the spa system functions, and one or more controlled
devices. The system and method exercises the controlled devices
during a testing regime, and monitors electrical current drawn by
the spa system during the testing regime. The electrical current
drawn by the spa system during the testing regime can be compared
with an expected current draw specification.
Inventors: |
Tarpo; James L.; (Aliso
Viejo, CA) ; Buchman; Jeffrey A.; (Mission Viejo,
CA) |
Correspondence
Address: |
LAW OFFICES OF LARRY K. ROBERTS, INC.
2 Park Plaza
Suite 300
Irvine
CA
92614
US
|
Family ID: |
35055477 |
Appl. No.: |
11/590242 |
Filed: |
October 31, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10815556 |
Mar 31, 2004 |
7158909 |
|
|
11590242 |
Oct 31, 2006 |
|
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Current U.S.
Class: |
700/65 |
Current CPC
Class: |
A61H 33/005 20130101;
A61H 2201/5007 20130101; A61H 33/0087 20130101; A61H 33/601
20130101; A61H 33/60 20130101 |
Class at
Publication: |
700/065 |
International
Class: |
G05B 19/18 20060101
G05B019/18 |
Claims
1. A method for testing a spa system which includes a spa tub for
holding water, an electronic controller system which controls the
spa system functions, a plurality of controlled devices controlled
by the controller system including a pump for recirculating water
in the tub, and a heater for heating water, the method comprising:
electrically coupling a test station to the spa system; exercising
the plurality of controlled devices during a testing regime;
monitoring an electrical current drawn by the spa system;
determining whether the electrical current drawn by the spa system
during the testing regime is consistent with an expected current
profile; and disconnecting the test station from the spa
system.
2. The method of claim 1, further comprising: filling the spa tub
with water before exercising the plurality of controlled
devices.
3. The method of claim 1, wherein said exercising the plurality of
controlled devices comprises: conducting a pump cycle comprising
turning the pump on, running the pump for a time, and turning the
pump off.
4. The method of claim 1, wherein said exercising the plurality of
controlled devices comprises: turning the heater on, and
subsequently turning the heater off.
5. The method of claim 1, wherein said exercising the plurality of
controlled devices further comprises: turning a blower fan on, and
subsequently turning the fan off.
6. The method of claim 1, wherein said exercising the plurality of
controlled devices further comprises turning a spa light on, and
subsequently turning the spa light off.
7. The method of claim 1, wherein said exercising the plurality of
controlled devices comprises: sending a command or set of commands
from a test station to the electronic controller of the spa system
to turn on and turn off one or more of the controlled devices.
8. The method of claim 1, wherein said exercising the plurality of
controlled devices comprises: operating each of said plurality of
controlled devices one at a time to isolate the current drawn by
each controlled device.
9. The method of claim 1, wherein said exercising the plurality of
controlled devices comprises operating all of said controlled
devices simultaneously to measure a maximum current load of the
spa.
10. The method of claim 1, further comprising: generating a test
report indicative of operability of the spa under test during the
test regime.
11. The method of claim 1, wherein the test report includes listing
of test results for each controlled device, and reflects a pass or
fail test state.
12. The method of claim 1, further comprising: printing a
certificate indicative of a successive test result if the spa under
test operates normally during the testing regime.
13. The method of claim 1, further comprising: establishing a data
communication link between the spa controller and the test station;
periodically passing spa status data over the data communication
link from the spa controller to the test station indicative of a
status of the spa and the controlled devices; passing commands over
the data communication link from the test station to the spa
controller for execution by the spa controller.
14. The method of claim 1, wherein the spa system further includes
a spa control panel for entering spa commands, the method further
comprising: testing the spa control panel.
15. A test system for testing a spa system which includes a spa tub
for holding water, an electronic controller system which controls
the spa system functions, a plurality of controlled devices
controlled by the controller system including a pump for
recirculating water in the tub, and a heater for heating water, the
test system comprising: a current sensor for sensing a spa current
drawn by the spa system and providing a sensor signal indicative of
the spa current; a test computer system; a data link between the
spa controller system and the test computer system for transmitting
spa system data to the test computer system and commands from the
test computer system to the spa controller system; a set of test
instructions for execution by the test computer system for
generating a set of commands to the spa controller to exercise the
plurality of controlled devices during a testing regime; the test
computer system adapted to monitor said sensor signals during the
testing regime and to determine whether the electrical current
drawn by the spa system during the testing regime is within a
predetermined specification, the test system being disconnected
from the spa system during normal spa operation.
16. The system of claim 15, wherein said set of test instructions
comprises: an instruction set for conducting a pump cycle
comprising turning the pump on, running the pump for a time, and
turning the pump off.
17. The system of claim 15, wherein said set of test instructions
comprises: an instruction set for turning the heater on, and
subsequently turning the heater off.
18. The system of claim 15, wherein said set of test instructions
comprises: an instruction set for turning a blower fan on, and
subsequently turning the fan off.
19. The system of claim 15, wherein said set of test instructions
comprises: an instruction set for turning a spa light on, and
subsequently turning the spa light off.
20. A test system for testing a spa system which includes a spa tub
for holding water, an electronic controller system which controls
the spa system functions, a plurality of controlled devices
controlled by the controller system including a pump for
recirculating water in the tub, and a heater for heating water, the
test system comprising: means for sensing a spa current drawn by
the spa system and providing a sensor signal indicative of the spa
current; a test computer system; means for transmitting spa system
data to the test computer system and commands from the test
computer system to the spa controller system; a set of test
instructions for execution by the test computer system for
generating a set of commands to the spa controller to exercise the
plurality of controlled devices during a testing regime; the test
computer system adapted to monitor said sensor signals during the
testing regime and to determine whether the electrical current
drawn by the spa system during the testing regime is within a
predetermined specification, said test system being disconnected
from the spa system during normal spa operation.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from application Ser. No.
10/815,556, filed Mar. 31, 2004, the entire contents of which are
incorporated herein by this reference.
REFERENCE TO A COMPUTER PROGRAM LISTING APPENDIX
[0002] A CD-R compact disc is submitted in duplicate, and contains
an appendix in the form of a file titled "MS2000-8000 Long.txt",
created Mar. 30, 2004, with a file size of 30,367 bytes (30,720
bytes on disc), the entire contents of which are incorporated
herein by this reference.
BACKGROUND
[0003] Prefabricated spa systems have become popular, and typically
include the spa tub, heater, water pump, electronic controller
system, lighting elements and associated plumbing. The spa system
can be assembled at a manufacturer's factory or distribution
center, before being delivered to the customer's site for
installation.
[0004] The spa systems typically have several devices or systems
under control of the system controller, and these must be connected
properly in the system to provide intended operational capability
of the spa system. If the spa system is delivered to a customer and
does not operate properly, a technician must be dispatched to the
installation site to troubleshoot and make repairs.
[0005] It would be advantageous to provide a method for testing spa
systems before shipment from the assembly location or shipment to
an installation location.
[0006] It would further be advantageous to provide a test system
for testing an assembled spa system before shipment from an
assembly location or shipment to an installation location.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Features and advantages of the disclosure will readily be
appreciated by persons skilled in the art from the following
detailed description when read in conjunction with the drawing
wherein:
[0008] FIG. 1 is a diagrammatic diagram of a spa system with
typical equipment and plumbing installed.
[0009] FIG. 2 is a diagrammatic block diagram illustrative of an
exemplary embodiment of a spa test system.
[0010] FIG. 2A is a functional block diagram of an exemplary
embodiment of a compiled application for executing test
scripts.
[0011] FIG. 3 is a schematic illustration of an exemplary
embodiment of a current sensor configuration.
[0012] FIG. 4 schematically illustrates an exemplary embodiment of
a spa controller comprising a controller printed circuit board.
[0013] FIGS. 5A and 5B set out in table form an exemplary set of
system parameters which are selectable by DIP switch settings on
the spa controller.
[0014] FIG. 6 shows a display screen shot of an exemplary
application panel, or operator screen, as displayed on the test
station display monitor.
[0015] FIG. 7 is an exemplary display screen shot illustrating a
graph display tab of an exemplary test application.
[0016] FIG. 8 is an exemplary display screen shot illustrating a
test configuration tab selected from the application panel.
[0017] FIG. 9 illustrates a display screen shot of an exemplary spa
configuration tab.
[0018] FIG. 10 is an exemplary display screen shot of a spa status
tab.
[0019] FIG. 11 shows a display screen shot of an exemplary
utilities tab of the application panel.
[0020] FIG. 11A shows an exemplary display screen shot of an
exemplary summary test results display.
[0021] FIG. 11B shows an exemplary display screen shot of exemplary
test results files.
[0022] FIGS. 11C-11E depict respectively an exemplary pass test
report, a fail test report, and a spa certificate.
[0023] FIG. 11F shows an exemplary display screen shot of a Colors
and Options tab.
[0024] FIG. 11G shows an exemplary display screen shot of a Device
Ratings tab.
[0025] FIG. 11H shows an exemplary display screen shot of an
exemplary Spa Configuration Tab.
[0026] FIG. 12 shows an exemplary diagnostic display panel.
DETAILED DESCRIPTION
[0027] In the following detailed description and in the several
figures of the drawing, like elements are identified with like
reference numerals.
[0028] FIG. 1 illustrates an overall block diagram of a spa system
with typical equipment and plumbing installed. The system includes
a spa 1 for bathers with water, and a control system 2 to activate
and manage the various parameters of the spa. Connected to the spa
1 through a series of plumbing lines 13 are pumps 4 and 5 for
pumping water, a skimmer 12 for cleaning the surface of the spa, a
filter 20 for removing particulate impurities in the water, an air
blower 6 for delivering therapy bubbles to the spa through air pipe
19, and an electric heater 3 for maintaining the temperature of the
spa at a temperature set by the user. The heater 3 in this
embodiment is an electric heater, but a gas heater can be used for
this purpose also. Generally, a light 7 is provided for internal
illumination of the water.
[0029] Service voltage power is supplied to the spa control system
at electrical service wiring 15, which can be 120V or 240V single
phase 60 cycle, 220V single phase 50 cycle, or any other generally
accepted power service suitable for commercial or residential
service. An earth ground 16 is connected to the control system and
there through to all electrical components which carry service
voltage power and all metal parts. Electrically connected to the
control system through respective cables 9 and 11 are the control
panels 8 and 10. All components powered by the control system are
connected by cables 14 suitable for carrying appropriate levels of
voltage and current to properly operate the spa.
[0030] Water is drawn to the plumbing system generally through the
skimmer 12 or suction fittings 17, and discharged back into the spa
through therapy jets 18.
[0031] An exemplary embodiment of a spa test system 50 is shown in
diagrammatic form in FIG. 2, for testing features of a spa 1. This
exemplary system includes a personal computer or work station 52,
connected to a printer 54 for printing test reports and
certificates and other records. A bar code scanner 56 is connected
to an I/O port of the computer 52, and can be used to scan a bar
code on the spa under test. This can facilitate automated capture
of data pertaining to the spa under test, e.g, the spa system
serial number as well as the serial number of spa components such
as pumps. The computer display monitor can include touchscreen
capability. Alternatively, or in addition, the user can interact
with the computer by keyboard, mouse or other input means.
[0032] The system 50 further includes a data acquisition module 60
which is connected to a USB port of the computer system. The module
60 has an input port connected to a current sensor coupled to line
1 of service lines 15A-15C, to provide a means of power input
current sensing.
[0033] In an exemplary embodiment, the data acquisition module is a
commercially available device, e.g. the National Instruments
DAQPad-602-E, a rack-mountable device with a 68-pin SCSI II male
connector. This device is a USB-compatible multi-function data
acquisition device, with analog, digital and timing I/O functions.
This exemplary device includes a 12-bit analog-to-digital-converter
(ADC), two digital-to-analog converters (DACs), TTL-compatible
digital I/O and counter-timers for timing I/O. Of course, other
types of circuits and devices can alternatively be used in the
system.
[0034] The system 50 further includes a current sensor 70 for
sensing the current being drawn by the spa 1. FIG. 3 is a schematic
illustration of an exemplary embodiment of a current sensor
configuration suitable for the purpose. The service wiring 15 is
passed through the sensor 70 from the line voltage source to the
spa 1 under test. One service wire 15A is connected through a
sensor module 74 and is passed on with the other wires (15B, ground
16 and neutral 15C) to a wiring plug 78 for connection to the line
voltage connector for the spa 1. The sensor module senses the
current being drawn on wire 15A, and provides a dc readout voltage
at port 76. In an exemplary embodiment, the sensor module 74 is a
commercially available unit, e.g., the Hawkeye H922 current
transducer marketed by Veris Industries. The dc readout voltage for
this transducer is a linear output indicative of the sensed
amperage.
[0035] The port 76 of the current sensor is connected to the data
acquisition module, where the dc readout voltage is converted to
digital form, and the digitized value is passed to the test station
computer for use in the spa test.
[0036] In an exemplary embodiment, a serial port of the test
station computer 52 is connected to a serial port of the electronic
controller of the spa 1 through a voltage level shifting adapter
80. The adapter 80 converts between RS-232 signal levels of the
computer serial port and SPI protocol TTL signal levels which are
compatible with the microcomputer comprising the electronic
controller of the spa. In an exemplary embodiment, the adapter
module 80 can include a MAX 232 RS-232 driver receiver device,
marketed by Maxim, or an equivalent, for performing the level
shifting. For some applications, the adapter 80 may be omitted,
e.g. in a design in which the TTL conversion is performed on the
controller board of the spa, and RS-232 signals are communicated
between the test station computer and an RS-232 port on the spa
controller board. A serial data stream can be passed between the
computer and the spa controller, allowing data and commands to be
passed from the computer to the spa controller, and for status and
other data to be passed from the spa to the computer 52.
[0037] In an exemplary embodiment, the test station 50 is connected
via an internet connection to a remote server site 90, which can be
employed to store and process test result files uploaded by the
test station to the remote server. In other embodiments, the test
station does not include a facility for uploading the test
files.
[0038] FIG. 4 schematically illustrates an exemplary embodiment of
a spa controller 2 comprising a controller printed circuit board
110, having a conductor pattern formed thereon and populated by
various components, including relays, terminal blocks, dip switch
blocks 184A, 184B, and a microcomputer 150. The controller board
can employ power and signal routing features as described in
pending application Ser. No. 10/677,510, entitled Controller System
for Bathing Installation, filed Oct. 2, 2003, the entire contents
of which are incorporated herein. In an exemplary embodiment, the
microcomputer is a PIC 18F6620 microcomputer, although other
microprocessors can alternatively be employed. The controller 2
further includes a serial data bus port 140 which is connected to
the test station computer 52 through the level shifting module 70.
In an exemplary embodiment, the port 140 provides full duplex
serial data bus connections allowing signals to be passed in both
directions simultaneously between the computer and the controller
2. The terminals of the port 140 are coupled to terminals of the
microcomputer 150, e.g. through buffer circuits well known in the
art.
[0039] The controller 2 in an exemplary embodiment includes two DIP
switch assemblies 184A, 184B, which can be set at the factory or by
a service technician to setting indicative of settings of the
controller or a particular configuration of the spa 1. FIGS. 5A and
5B set out in table form an exemplary set of system parameters
which are selectable by the DIP switch settings. The DIP switch
settings can be read by the microprocessor 150, and can be passed
to the test station through ADCM (advanced diagnostic control and
monitoring) port 140 during a test of the spa.
[0040] Data can therefore be exchanged between the spa controller 2
and external systems such as the test station computer. In an
exemplary embodiment, the data can be in the form of data packets
of a predetermined protocol.
[0041] In an exemplary embodiment, the adapter 80 receives SPI
(Serial Peripheral Interface Protocol) data from the spa controller
2, and RS-232 serial data from the test station computer, and
performs a conversion between the voltage levels and timing of the
SPI and RS-232 signals. The burst clock rate for the SPI data in
this exemplary embodiment is 375 kHz (24 MHz/64), meaning the worst
possible case would be 46.875 microseconds between bytes, but if
necessary the controller can space the bytes somewhat further
apart. The bit rate for the RS-232 serial communication data will
be 38400 baud, meaning characters may be no more than about 260
microseconds apart. In other embodiments, the spa controller 2 can
include an integrated adapter, so that it receives the RS-232 data
from the test station computer directly.
[0042] The adapter 80 detects the start of an SPI transmission. For
example, it can do this by detecting a timeout after the last
(successful or unsuccessful) transmission, or by monitoring (a copy
of) the SPI select signal manually.
[0043] Upon the start of an SPI transmission, the data coming from
the spa controller 2 can be in the following format in one
exemplary embodiment: TABLE-US-00001 byte magic-1 (0x55) byte
magic-2 (0x5A) byte inverted Length byte length (length of
everything after this `length` byte but before`checksum` byte) byte
packet type byte data bytes . . . byte checksum (an 8-bit checksum
of everything after `length` byte but before this `checksum`
byte)
[0044] The SPI transmission will end after and exactly after the
`checksum` byte. This could be used as another level of
verification (specifically, if the transmission ends before the
`checksum` byte, the transmission should be considered
invalid).
[0045] The format of the data coming from the adapter 80 will be
similar: TABLE-US-00002 byte magic-1 (0x55) byte magic-2 (0x5A)
byte inverted Length byte length (length of everything after this
`length` byte but before `checksum` byte) byte packet Type byte . .
. data . . . byte checksum (an 8-bit checksum of everything after
`length` byte but before this `checksum` byte)
[0046] In an exemplary embodiment, the data is sent in both
directions in the same phase; i.e., while the spa controller 2 is
sending magic-1, the adapter 80 is also sending magic-1, etc.
Magic-1 and Magic-2 are bit sequences that would be highly unusual
to find in real data, and is used for synchronization. The adapter
80 tells the spa controller 2 the length it has to send before it
knows how many bytes the controller will send (and thus for how
many bytes the controller will send clocks). Thus if the length the
adapter 80 sends is greater than the length the controller 2 sends,
the adapter will use the length the controller sends to determine
how much to actually send and when to send the checksum byte, even
though it will find out too late to send its `invertedLength` and
`length` parameters correctly.
[0047] In an exemplary embodiment, the adapter passes through as
much data as it gets as soon as it reasonably can, in each
direction independently. Actual packets from the external source,
e.g., the test station computer, may or may not be broken up into
multiple SPI packets, and/or one packet from the computer 52 may
end and another may start within one SPI packet.
[0048] Communication from the test station computer 52 in an
exemplary embodiment is full duplex asynchronous serial at 38.4
kbaud, 8-N-1, i.e. 8 data bits, no parity, 1 stop bit. Examples of
the data format are summarized in the Table below. TABLE-US-00003
Packet Type Packet Name 0x01 Status Update 0x02 Board and System
Serials 0x03 Fault Log Entries 0x81 Button Push 0x82 Settings Poke
0x83 Programming Poke 0x84 Requests
[0049] In an exemplary embodiment, the status packet includes
status data about the configuration of the spa under test, its
current status as well as that of the installed devices, and the
states of the spa controller board DIP switch settings. The board
and system serials packet can include serial number data for the
controller 2 as well as for the installed devices in the device
under test.
[0050] The fault log packets can include fault data which is logged
by the spa controller and can be uploaded to the test station or to
a remote server.
[0051] In an exemplary embodiment, the button push packet includes
control commands or data for the spa controller to act on. These
button commands can be issued by the test station during a test
routine. The data in the packet can include a Button Metacode. In
an exemplary embodiment, the Button Metacode is one of the
following:
[0052] Temperature Up/Warm=1
[0053] Temperature Down/Cool=2
[0054] Temperature/UpDown=3
[0055] TimeChemistry=5
[0056] TimeOnly=6
[0057] ChemistryOnly=7
[0058] Mode=8
[0059] Invert=9
[0060] Jets1=11
[0061] Jets2=12
[0062] Jets3=13
[0063] Jets4=14
[0064] Blower=16
[0065] Spa Light=18
[0066] Fiber=19
[0067] EitherLight=20
[0068] Option=24
[0069] Mister=25
[0070] Color Kinetics Mode=26
[0071] Color Kinetics Option (Color/Speed)=27
[0072] Color Kinetics Intensity=28
[0073] The following metacodes are only effective when the
receiving system is in Priming mode:
[0074] Pump 0 Only=50
[0075] Fiber Light Only=51
[0076] Fiber Wheel Only=52
[0077] Spa Light Only=53
[0078] Ozone Without Timeout=54
[0079] Pump 1 Only=55
[0080] Alarm=56
[0081] In an exemplary embodiment, the programming poke packet can
be used to set the time on the spa controller, as well as filter
programmable time values. The requests packet can be used to send
instructions to the spa controller from the test station to return
a board and serials packet, to transmit its fault log in a fault
packet, to place the spa in a priming mode (during which most tests
are conducted by the test station), or to transmit its
configuration settings.
[0082] The settings poke packet can be used, in an exemplary
embodiment, to lock the spa controller panel during tests, and to
set the spa temperature for tests.
[0083] In an exemplary embodiment, early in each packet is a
`packetType` field. Its exact meaning may vary with the system
software identification (SSID), but each packet includes the
direction bit. For example, if bit 7 is "on" (0x81, for example),
the packet has been sent to the spa controller 2, and does not
include the SSID (in this exemplary embodiment, packets are sent to
the controller 2 only once packets from the controller 2 have been
received by the adapter 80, and so resending the SSID would be
superfluous). If bit 7 of a given packet is "off" (0x01, for
example), this signifies that the packet has been sent from the
controller 2, and does include the SSID.
[0084] In one exemplary embodiment, all packets use an identical
format up through the `packetType` field. (This includes a two-byte
magic, a one-byte length preceded by an inverted copy of itself,
and a five-byte Chip Serial Number structure.) Furthermore, all
packets sent from the controller use an identical format up through
the `ASSID_version` field.
[0085] In an exemplary embodiment, the spa controller 2 sends only
Status Update packets unless it gets a Request packet asking for
another type of packet. Only one other type of packet is sent at a
time from the controller, and when there is another type of packet
sent from the controller, it is only sent every other time. Thus
there are always Status Update packets coming at least every other
packet in this embodiment.
[0086] The data frequency is switchable for packets sent from the
controller 2 in one exemplary embodiment. The slow (default) data
frequency is a packet every 0.8 seconds; an exemplary fast data
frequency is around 10 packets per second.
[0087] The test station computer 52 is programmed with a test
algorithm designed to exercise the components of the spa under
test. In one exemplary embodiment, the test algorithm is defined by
test scripts which are run by a compiled Labview application
installed on the test station computer 52. Labview is a
commercially available program, marketed by National Instruments.
The compiled program processes the test scripts which are designed
to perform the test sequences. FIG. 2A is a functional block
diagram of an exemplary embodiment of a compiled application 300
for executing the test scripts. The application includes a user
interface module 302, which is responsive to user interface
devices, such as the keyboard, mouse, touchscreen, e.g. to process
button pushes. The user interface module exchanges data with a
system configuration module 304, which stores data regarding the
spa system configurations. A software data acquisition module 306
receives data from the module 60, to provide spa current data to a
script engine 308. The script engine 308 is a Labview interpreter,
which interprets and executes the test scripts comprising the test
script files 310. The script engine 308 sends commands to an ADCM
interface module 312, which formats the commands into appropriate
serial data packets sent to the RS-232 serial port of the test
computer connected to the adapter 70, and which interprets data
from the serial port. The interface module 312 also receives
commands from, and sends ADCM data to the user interface module
302. The script engine also provides test data to a reporting and
logging module 314, which services the test station display to
provide data displayed on the test station monitor, provides test
result files, and provides remote services, such as sending test
result files to a remote server.
[0088] An exemplary test script is set out in the Appendix set out
in the incorporated file MS2000-8000 Long.txt. An exemplary spa
test routine is described below. It will be understood that the
following description is merely exemplary, and that other
embodiments may implement different test scripts and routines.
[0089] Spa Test Overview The Spa Test Station 50 in this embodiment
gives the user the opportunity to control and measure events and
states of the spa in a highly repeatable manner. In an exemplary
embodiment, this is achieved by running a Test Script that modifies
the states of spa equipment (pumps, blowers, etc.) in the desired
way while taking current draw measurements and serial ADCM status
as confirmation of correct operation. In an exemplary embodiment,
the spa test is a wet test, performed with water in the spa tub.
The spa is filled with sufficient water for the test.
[0090] In an exemplary embodiment, two types of data are archived
during a test run. One type is the Test Results Data. These results
appear in text format on the main screen, and are logged to the
local hard drive in the c:\Fast Spa Test\Test Results directory as
the test runs. They can be subsequently transferred to a remote
server site upon test completion, using an internet connection. A
second type of data is ADCM data. This is serial status information
from the controller, acquired at regular intervals and sent to the
remote server, FTP site upon test completion. This "history of
operation" logging provides the user several post-test
troubleshooting tools. The data can be processed and viewed.
[0091] Upon completion of a test run, the following printed reports
can be made available in an exemplary embodiment. A Test Report is
a complete copy of all measurements taken during the test run. It
is essentially a copy of the data that appears in the Test Results
table during a test run. A second printed report is a Spa
Certificate. If a test run is completed without any failures, the
tester will optionally print out a certificate of verification for
the spa.
[0092] An exemplary test regime carried out by the test station is
described by the following process steps:
[0093] 1. Initialize the test script variables, and check
operations, e.g. check for correct spa water level, diverter valves
set to center position, visual spa inspection.
[0094] 2. Evaluate the spa system configuration for the spa under
test.
[0095] 3. Initialize the spa for test.
[0096] 4. Main Test: [0097] a. Test Pump 1 operation. [0098] b.
Test Pump 2 operation. [0099] c. Test Pump 3 operation. [0100] d.
Test Pump 4 operation. [0101] e. Test Pump 5 operation. [0102] f.
Test Blower operation. [0103] g. Test Spa light operation. [0104]
h. Test Fiber Light operation. [0105] i. Test Mister operation.
[0106] j. Test Option operation. [0107] k. Test Panel operation.
[0108] l. Test Filter. [0109] m. Test Heater operation. [0110] n.
Test maximum current load operation by turning on all spa current
load components.
[0111] 6. Reset Spa under test.
[0112] 7. Print report and test certificate.
[0113] 8. Optionally upload test results to remote server.
[0114] In an exemplary embodiment, the test station will set the
spa controller to a priming mode to run the tests which do not
involve the heater. This is a convenient mode which allows the
non-heater components to be exercised. The spa controller in this
embodiment is placed in an operating mode to test the heater
operation, and the spa water temperature, i.e. a thermostat
temperature, is set to a set point which will cause the heater to
turn on in normal conditions. The spa current magnitude is
monitored during the various tests to determine whether the current
draw is within specifications as the respective spa components are
turned on and off. Since the nominal current draw for each of the
components and for each component state (e.g. low speed, high
speed, etc.) is stored in advance in the spa configuration files on
the test station, the application software compares the actual
current as measured by the current sensor 70 to the nominal current
for the respective device. There is also a test for the maximum
current load, with all devices turned on.
[0115] The function and operation of an exemplary embodiment of a
test station and test routines which can be run by this exemplary
embodiment are described below.
[0116] Control and Display Section FIG. 6 shows a display screen
shot of an exemplary application panel, or operator screen, as
displayed on the test station display monitor. The upper section of
the application panel on the test station display has several
controls and indicators used to operate and monitor the
application. The "station selector" control allows the user to
connect to one of four spas. In this embodiment, only one spa at a
time is tested. This selector is not enabled during a test run.
[0117] The "Tab Selection" Control (FIG. 6) is used to select the
viewing tab. The available tabs for an exemplary embodiment,
described more fully below, are Test Results, Graph Display, Test
Configuration, Spa Configuration, Spa Status, and Utilities.
[0118] Checking the "Pause Delay" (FIG. 6) will pause the test
results table display and the graph display. This allows the user
to view information without the automatic scrolling feature of
these two indicators being active.
[0119] The Current Display indicator (FIG. 6) shows the total
current draw of the spa, as measured by the current sensor 70.
[0120] The Temperature Control/Display control (FIG. 6) indicates
the currently programmed temperature as read from the spa
controller. Additionally, it can be used to set the temperature.
When the temperature is changed, the control will change color to
indicate the change has been made. It will return to blue when the
temperature is verified from the controller. Invalid temperatures
are rejected by the controller in this embodiment.
[0121] The controls used to operate and monitor the various
configured pumps, blowers, lights, etc., are displayed on the
application panel (FIG. 6). All controls except for the Heater and
Circulation pump (not user controllable), contain a push-button
operation as well as an animation that represents the state of the
device. These controls act as indicators during a test routine.
When the test script is not running, the controls become buttons
for interactive operation of the spa in much the same way as the
panel control buttons.
[0122] When the Pump control (FIG. 6) is pushed, the pump state is
toggled through all of the configured pump speeds (Off, Low, High).
The Pump 4 and Pump 5 controls, if enabled, allow the user to
control these special single-speed pumps. The Circulation Pump
control is active with the Spa controller in the Priming Mode
(activated by the reset button). In this mode the pump can be
controlled as the other pumps. In normal spa mode, i.e. a mode in
which the spa controller is controlling the spa operation as it is
designed to do, the firmware of the spa controller has full control
of the Circulation pump.
[0123] When the Blower control (FIG. 6) is pushed, the blower is
toggled through all of the configured speeds (Off, Low, Med,
High).
[0124] When the Option control is pushed, the user equipment is
toggled On and Off. In an exemplary embodiment, this control will
only be available if the spa controller is not set up to have a
Mister.
[0125] When the Mister control (FIG. 6) is pushed, the mister pump
is toggled On and Off, if the spa controller is set up to use the
option relay for mister control.
[0126] When the Light control (FIG. 6) is pushed, the light state
is toggled through all of the configured light levels (Off, Low,
Med, High).
[0127] When the Fiber control (FIG. 6) is pushed, the Fiber
equipment is toggled through all of the available modes (Off,
Fiber+Wheel, Fiber).
[0128] The Reset button provides the user the ability to quickly
de-energize all spa components.
[0129] Controls for devices not available, or not enabled by the
spa controller DIP switches, will appear with greyed out
labels.
[0130] The application panel (FIG. 6) includes several
miscellaneous indicator LEDs. A Network Enabled LED indicates that
the network option has been enabled in the User Settings file and
that the last attempt to log in to the remote FTP server site was
successful. The Ozone LED indicates the ozone relay has been
activated. If no ozonator is present, there is no effect. The
Cleanup Cycle LED indicates that the spa cleanup cycle is
activated. The Filter 1/Filter 2 Cycle LEDs indicate that a spa
filter cycle is activated.
[0131] Still referring to FIG. 6, the Run Test button is used to
initiate a test run, beginning with the `configure test` actions.
When the button has a red blinking background, it indicates that
the user should finish the test initialization actions (Test
Configuration and Spa Configuration) and press the button to
continue. The Abort Test button will abort a test script at the end
of the current action. There are no `End of Test` actions performed
when this button is hit. The user may want to hit the Reset button
after a test abort. Test reports are available for print when this
action is taken, but not certificates. If this button is activated
during the start of test procedure (operator entry), the test start
is cancelled. The Stop Test button only becomes visible (in lieu of
the `Run Test` button) when the test script has completed one pass
through the script. It gives the operator the ability to perform an
orderly test stop after a number of test loops have been completed.
Test reports are available for print when this action is taken, as
well as spa certificates.
[0132] A No Data Acquisition indicator is only displayed if the
data acquisition module is not detected by the program. Test
scripts may still be run which do not require measured current
(ADCM only). The Status Bar is located at the bottom of the panel
(FIG. 6). It displays current information regarding the test. The
Test Time indicator displays the time elapsed since the beginning
of the test run. The Test Fails indicator shows the number of
measurement failures since the test was started. The Spa Status
indicator is used to indicate that a spa controller is not in
communication with the test station. The system continually tries
to maintain communication with a controller via the ADCM port 140.
If a spa controller is not present this indicator will indicate
`disconnected`. The other valid modes displayed in this indicator
are: Startup, Priming Mode, Normal. The Script Command indicator
displays the number of the currently running script command. The
Test Loops indicator displays which iteration of the main test loop
is currently running. The Error Message indicator displays the most
recent error message logged into the Error Display. This error can
be cleared once observed so that subsequent errors continue to
alert the user to additional problems.
[0133] The various areas (tabs) of the application are discussed in
this section.
[0134] Test Results Tab The Test Results Table under this tab
displays the results of all measurements taken by the test script.
The exemplary application panel of FIG. 6 shows the panel with the
Test Results tab selected.
[0135] The Error Message Display contains a list of all errors
encountered by the program. The background and text change color if
errors are present. This display is cleared at the beginning of
each test.
[0136] The Test Loops control selects the number of times the test
runs through the main body of the script before the test ends. Note
that this control may also be controlled by the test script.
[0137] Checking the Single-Stepping box allows the user to pause
prior to each test script command being executed. When the program
is paused, the large Resume Test button will be visible and
blinking.
[0138] Graph Display Tab. This tab displays a running history
buffer of test events and current levels. Graphs are cleared at the
beginning of a test run, or the beginning of a new spa connection.
The sample interval and buffer size of the graph are configurable
on the Test Configuration, tab. FIG. 7 is an exemplary display
screen shot illustrating the graph display tab.
[0139] The upper section of the Current Draw graph displays the
current draw as sampled at the interval specified. The lower
portion of the graph converts the states of various spa devices, as
well as the current reading, into a strip-chart format. The graph
records as long as a controller is connected. The time span of the
graph can be changed by entering a different value into the left,
or right X-axis coordinates. The Clear graph button allows the user
to restart the graph at any time. The graph is also cleared
whenever a different spa is connected to the station.
[0140] Test Configuration Tab. This tab is viewable at any time,
and invoked when a test is run. It provides the Operator and Test
Script selection. FIG. 8 is an exemplary display screen shot
illustrating the test configuration tab selected from the
application panel.
[0141] The Operator Selection listbox contains the pre-defined list
of operators (as configured). The operator selection is used for
logging purposes only. The name of the operator appears in the test
result file.
[0142] The Test Script File Selection listbox contains the names of
all Test Scripts that have been loaded into the test station
application to run on the tester. This is the "test program" to be
run on the spa. The test scripts, in an exemplary embodiment, are
designed to test the configured device connections, operation, and
current draws at the available speeds. ADCM status from the spa
controller allows the test script to determine what is available to
test.
[0143] Spa Configuration Tab. This tab is invoked when a test is
run. At that time, the Device Status indicators are updated to
reflect the configuration of the presently connected spa. When the
operator selects a spa model from the drop-down list, all model
selections and options will populate this screen. If the correct
model has been selected, the only remaining red selections will
typically be the Spa S/N and perhaps the Tub Color. FIG. 9
illustrates a display screen shot of an exemplary spa configuration
tab. In this embodiment, mismatches between the selected, and
connected spa can be indicated in red. Red selections that are not
<Select> are interpreted as "The wrong spa selection" and the
controls are disabled. The operator will not be allowed to start a
test on the spa if this occurs. The basic two types of violations
are 1) Device configured, but not seen on the connected spa, or 2)
Device seen on connected spa, but configured as "None" in the User
Settings.
[0144] The Spa S/N is required to commence a test in this exemplary
embodiment. All other S/N's are recommended but optional.
[0145] There are drop-down lists originating from the information
entered via the User Settings utility, for spa equipment and
components, including pump models, blower models, heater models,
spa cabinets, tub colors, etc. This information includes a set of
options defined by the user, and is kept in the user configuration
files.
[0146] The Selected Options selections have no functional effect on
the test, but allow the program to log the contents of the spa for
tracking purposes. The same applies to the Comments field and Aux
Panels field. The model selections "tell" the program how much
current each device should draw in the different states. If these
are not selected correctly, test failures will occur.
[0147] The Reload Last Spa button frees the operator from having to
re-enter the 0S/N's of a spa should the test need to be
restarted.
[0148] In an exemplary embodiment, the test station. Bar Code
reader is programmed to accept a S/N then proceed to the next
available S/N field.
[0149] For each spa component that the software detects, the user
is offered an entry for Model and S/N. (If there is no pump 3, for
example, then these options are disabled for that device). The test
station software receives the spa component information by reading
the ADCM status packets received from the spa under test.
[0150] Spa Status Tab. The spa status tab shows the parsed results
of the ADCM packets retrieved from the unit on a continual basis.
This information, plus the Current Draw reading make up the ADCM
data packets which can optionally be uploaded to the remote FTP
server.
[0151] The Controller Type indicates a particular spa controller
model. The Firmware and S/N numbers are written into memory at the
controller manufacturer and can be viewed here. Several Spa Status
LED's indicate the status of several spa characteristics (e.g.
Celsius mode, Mister Enabled, Option Enabled, etc.)
[0152] The DIP Switch Status indicator shows the visual and
hexadecimal setting of the DIP switches on the spa controller unit
as defined at the last power-up sequence, by receipt of the ADCM
status data packet from the spa controller. In one exemplary
embodiment, the test scripts are written to fully test the
functionality of the configured spa devices. The DIP switch states
are processed at the beginning of the test to determine what test
actions are to be taken. In one exemplary embodiment, the DIP
switches should be correctly set with power cycled if necessary,
before the test is run, so that all devices are correctly tested
for a given spa model.
[0153] Utilities Tab. This tab contains several utility programs
within the test application. FIG. 11 shows a display screen shot of
an exemplary utilities tab of the application panel.
[0154] One utility is the Fault Log. One type of spa controller can
track observed failures and store them in non-volatile memory on
the spa controller. Pressing the update button causes the program
to retrieve and display these internal fault messages.
[0155] The Check FTP Connect button checks the status of the
network connection, as well as the FTP user name. If the system can
successfully log in to the site, a `pass` message is temporarily
shown in the upper panel section, otherwise fail is indicated and
the Network LED is turned off.
[0156] The Re-Print Last Report feature is available to enable the
user to generate multiple printouts of the report, or recover from
printer difficulties at the time of the original test results
report.
[0157] The Re-Print Last Certificate feature is available to enable
the user to generate multiple certificates, or recover from printer
difficulties at the time of the original certificate print.
[0158] The Viewing test Summary Log utility allows the user to
quickly view the summary test results of units run on the test
station during a given time interval. The time span is modifiable,
and printed reports are available. FIG. 11A shows an exemplary
display screen shot of an exemplary summary test results
display.
[0159] The Viewing Test Result Files viewer is provided to quickly
access the details of the test results gathered by the test
station. Files are available on a Model/Serial Number basis. These
are the same files that can be sent to the FTP site upon test
completion. FIG. 11B shows an exemplary display screen shot of an
exemplary test results file.
[0160] The User Settings Utility gives the spa test application the
ability to adapt the test behavior to accommodate a specific user
(based on his pumps, blowers, heaters, misters, options, special
options, cabinet types, colors, tub materials etc.). Setting up the
parameters in this utility is the first step in preparing the test
station for use. This utility is entered from the "utilities" tab
on the application panel. The following Table shows a sample of a
file generated by this utility. TABLE-US-00004 TABLE User Settings
File Format [COMPANY] Company=BALBOA FTP_Address=www.spatest.com
FTP_Username=BALBOAFTP NetworkEnable=1 [TESTER] TestStations=Test
Bay 1,Test Bay 2,Test Bay 3,Test Bay 4
Operators=Operator1,Operator2,Operator3,Operator4 [SPA MODELS]
Spa0=EL8000-No Circ,0x406,0x38F,Maple
Stain,Acrylic,<Select>,ML700,2,Century,Century,Century,Pump 4
Model,Pump 5 Model,None,Mark,5.5KW,LED Type,Bulb Type,ACME Mister
Pump,one,Stereo, Chemical Dispenser,Skimmer
Spa1=EL8000-Circ,0x702,0x30F,Cedar Stain,Fiberglass,Galaxy
Green,ML700,1,Century,Century,Century,None,None,CIRC_Pump
1,Mark,5.5KW,None,Bulb Type,ACME Mister
Pump,None,Waterfall,-,Chemical Dispenser
Spa2=EL5000-Circ-Fiber,0x104,0x48E,Gray Stain,Acrylic,Flourescent
Pink,ML700,1,BX4101,BX4101,None,None,None,Century
Circ,BX1004,5.5KW,LED Type,Bulb
Type,None,Balboa-240V,Waterfall,Stereo,Chemical
Dispenser,Skimmer,Fountain of Youth Spa3=EL8000-No
Circ,0x406,0x38F,Maple
Stain,Acrylic,<Select>,ML700,1,Century,Century,Century,None,None,Non-
e,Mark,5.5 KW,LED Type,Bulb Type,ACME Mister
Pump,None,Waterfall,-,Chemical Dispenser,Skimmer Spa4=EL5000-No
Circ-Fiber,0x104,0x49E,Maple
Stain,Acrylic,Seaspray,ML700,1,BX4101,BX4101,None,None,None,None,BX1004,
5.5KW, LED Type,None,None,Balboa-240V,Waterfall,-,Chemical
Dispenser,-,Fountain of Youth Spa5=EL2000-Circ-No
Blower,0x104,0x92,Gray
Stain,Acrylic,Carribean,ML700,1,BX4101,BX4101,None,None,None,Century
Circ,None,5.5KW,LED Type,None,None,None,Waterfall,Stereo,Chemical
Dispenser, Fountain of Youth Spa6=EL2000-No
Circ-Blower,0x100,0x96,Maple
Stain,Acrylic,Seaspray,ML700,1,BX4101,BX4101,None,None,None,None,Mark,
5.5KW,LED Type,None,None,None,Waterfall,-,-,Skimmer,Fountain of
Youth [SPA MATERIALS] Cabinets=Cedar Stain,Maple Stain,Gray Stain
TubMaterials=Acrylic,Fiberglass TubColors=Galaxy
Green,Carribean,Seaspray,Flourescent Pink,Purple-ish Green
Panels=ML500,ML700,ML900 Options=Waterfall,Stereo,Chemical
Dispenser,Skimmer,Fountain of Youth [PUMPS] Pump0=BX4101,4.00,8.00
Pump1=BX4102,6.00,10.00 Pump2=BX4103,8.00,12.00
Pump3=Century,3.00,8.00 FAST Test User Manual Rev. Date: Oct. 1,
2003 [CIRC_PUMPS] Circ0=CIRC_Pump 1,1.00 Circ1=CIRC_Pump 2,2.50
Circ2=Century Circ,4.40 [BLOWERS] Blower0=BX1002,2.50,5.00,8.00
Blower1=BX1004,4.50,8.00,11.00 Blower2=BX1006,6.50,9.00,13.00
Blower3=BX1008,7.50,10.00,14.00 Blower4=BX10010,8.50,12.00,14.00
Blower5=Mark,2.10,2.90,3.50 [SPA_LIGHTS]
Light0=Incandescent,0.05,0.10,0.20 Light1=LED Type,0.03,0.09,0.15
[FIBER] Fiber0=Bulb Type,0.00,0.00 Fiber1=LED Type,0.40,1.10
[OPTIONS] Option0=ACME Mister Pump,2.25 Option1=ACE Mister
Pump,1.75 Option2=User Device1,5.00 Option3=User Device2,10.00
[OZONATORS] Ozonator0=Balboa-120V,5.50 Ozonator1=Balboa-240V,7.50
Ozonator2=Brand-X,11.50 [HEATERS] Heater0=5.5KW,20.50
Heater1=4.0KW,16.80 [CERTIFICATE] Cert_JPEG=C:\\FAST Spa
Test\\Files\\Certificate\\Generic Certificate.jpg
Cert_Text=Congratulations on purchasing your new Spa.
Cert_ClosingComment=We hope you will enjoy your spa for many years
to come. Cert_Signatory=John L. Smith, Director of All
Cert_SignatureFile=C:\\FAST Spa Test\\Files\\Certificate\\John
Smith.jpg [SETTINGS] PrintMode=1 CertificateMode=1 TestLogMode=0
ResultsTableSize=1000 GraphPoints=500 GraphSampleInt=4
[0161] The User Profile Tab under the User Settings utility
provides report and Certificate print options. Test reports and spa
certificates are available upon test completion. An exemplary pass
test report, a fail test report and a spa certificate are shown in
FIGS. 11C-11E. The "Test Results Print," and "Certificate Print"
listboxes offer the user the following options for printing:
[0162] 1. None--No printouts are generated for the selected
item.
[0163] 2. Automatic--Automatic printout of test reports, Automatic
certificate printouts on a passed test.
[0164] 3. Prompt--Prompt for printing report at the end of the test
run. Same for certificate if the test is passed.
[0165] Test results are written to a file based on the Model and
serial number of the spa entered at run-time. Multiple runs on the
same model and serial number are appended to the existing file. The
Test Result File indicator shows the file name assigned by the
program.
[0166] A Test Log Mode selector allows the measurements written to
the Test Results file to be handled in the following way:
[0167] 1. All results--Header and all test results are written to
the results file for this S/N.
[0168] 2. Fails Only--Header and failed readings are written to the
results for this S/N.
[0169] 3. No Results--No results are written. This mode should only
be used during troubleshooting.
[0170] The Colors and Options tab under the User Settings tab
stores entries used for spa feature tracking and record keeping.
These options are recorded to the Test Results file and may appear
on the spa certificate. FIG. 11F shows an exemplary display screen
shot of the Colors and Options tab.
[0171] The Device Ratings Tab under the User Settings tab provides
a place to define all models used to build the various spa
products. For each device, there is a model description and a
nominal amperage draw for each of the speeds/states of the device.
For single speed devices, 0.0 is entered for all lower speeds that
do not apply. FIG. 11G shows an exemplary display screen shot of
the Device Ratings tab. In one exemplary embodiment, nominal
current draws less than 0.2 A will not be quantitatively checked by
the test script due to the sensitivity and resolution of the
current measurement hardware.
[0172] The Spa Configurations Tab under the User Settings tab is
where the tested spa configurations are created. Spas created here
are available to the operator in the drop-down list at test run
time. The upper section of this panel provides the interface for
modifying the configuration. The lower section (table) shows the
summary of what has been created. FIG. 11H shows an exemplary
display screen shot of an exemplary Spa Configuration Tab.
[0173] In an exemplary embodiment, upon completion of the necessary
User Settings actions, the station is ready to run a test on a
configured spa. Pressing the Run Test button (application panel,
FIG. 6) will initiate the sequence of Test Script/Operator
selection and Spa selection, and begin the test. Results will begin
to appear in the table.
[0174] The program can assist the operator in locating the cause
for test failures obtained during a test run. A diagnostic panel
displays the top reasons why a measurement may have failed a test.
To access the diagnostic panel, the user clicks, using the mouse,
in the row of the test results table where the failure occurred. If
the top reasons are determined not to be the cause of the failure,
the operator may then proceed with the fault tree diagnosis to
further locate the problem. An exemplary diagnostic display panel
is shown in FIG. 12, with a diagnostic message for a blower high
current failure.
[0175] In an exemplary embodiment, the test station is protected by
a security key. It is necessary to have the key installed in one of
the USB ports on the computer in order to launch the application.
If the key is not present, an error message will alert the user,
and the application will terminate. If the key is removed after the
application is started, the user will be given a warning that the
key can no longer be detected. After approximately 30 seconds the
application will terminate.
[0176] The test station and testing method can find use by spa
fabricators to test a fully assembled spa at a factory or
distribution center. Other exemplary applications include use to
test a fielded spa, e.g. by a service technician. The test station
application software can be loaded onto a laptop computer, and the
service technician can hook up the current sensor to the line
voltage connection to the spa with a data acquisition module as
needed, and the data connection between the computer and the spa
controller.
[0177] Although the foregoing has been a description and
illustration of specific embodiments of the invention, various
modifications and changes thereto can be made by persons skilled in
the art without departing from the scope and spirit of the
invention as defined by the following claims.
* * * * *