U.S. patent application number 15/840581 was filed with the patent office on 2018-06-14 for pump communication module, pump system using same and methods related thereto.
The applicant listed for this patent is Wayne/Scott Fetzer Company. Invention is credited to Tyler Aaron Lusebrink, Philip Anthony Mayleben, Joshua Michael Wilds.
Application Number | 20180163730 15/840581 |
Document ID | / |
Family ID | 62487744 |
Filed Date | 2018-06-14 |
United States Patent
Application |
20180163730 |
Kind Code |
A1 |
Wilds; Joshua Michael ; et
al. |
June 14, 2018 |
PUMP COMMUNICATION MODULE, PUMP SYSTEM USING SAME AND METHODS
RELATED THERETO
Abstract
A pump system comprising a primary AC pump, a control unit
having a wireless communication module, and a back-up battery for
powering the control unit. The wireless communication module is
configured to communicate via a primary wireless connection and
communicate via a secondary wireless connection. Additional pump
system components and various methods relating to same are further
disclosed herein.
Inventors: |
Wilds; Joshua Michael;
(Harrison, OH) ; Lusebrink; Tyler Aaron;
(Cincinnati, OH) ; Mayleben; Philip Anthony;
(Brookville, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Wayne/Scott Fetzer Company |
Westlake |
OH |
US |
|
|
Family ID: |
62487744 |
Appl. No.: |
15/840581 |
Filed: |
December 13, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62433772 |
Dec 13, 2016 |
|
|
|
62597407 |
Dec 11, 2017 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H04Q 2209/43 20130101;
G08C 2201/93 20130101; H04W 48/20 20130101; F04B 17/06 20130101;
F04B 49/065 20130101; F04D 25/068 20130101; G08C 2201/50 20130101;
F04D 15/0088 20130101; F04D 13/068 20130101; F04D 13/14 20130101;
F04D 13/086 20130101; H04W 24/04 20130101; F04D 15/0218 20130101;
G08C 17/02 20130101; H04Q 9/00 20130101; H04Q 2209/823 20130101;
G08C 2201/42 20130101 |
International
Class: |
F04D 15/02 20060101
F04D015/02; F04D 13/06 20060101 F04D013/06; F04D 13/08 20060101
F04D013/08; F04D 15/00 20060101 F04D015/00 |
Claims
1. A pump system comprising: a primary AC pump; a control unit
having a wireless communication circuit or module; and a back-up
battery for powering the control unit; wherein the wireless
communication circuit or module is configured to communicate via a
primary wireless connection and communicate via a secondary direct
wireless connection when the primary wireless connection is
unavailable.
2. The pump system of claim 1: wherein the primary wireless
connection is an internet connection and the control unit detects
internet access, and wherein the wireless communication circuit or
module communicates via the secondary direct wireless connection
when no internet access is detected.
3. The pump system of claim 1 further comprising a button
configured to establish the direct wireless connection.
4. The pump system of claim 1 further comprising a backup DC
pump.
5. The pump system of claim 1 wherein the wireless communication
circuit or module is configured to communicate via one of Wi-Fi,
Bluetooth, Bluetooth Low Energy, Near Field Communication, Radio
Frequency, Infrared, and Zigbee.
6. The pump system of claim 1 further comprising a remote
electronic device, wherein the remote electronic device is
configured to receive a notification from the control unit via the
Internet and via the direct wireless connection.
7. The pump system of claim 6 wherein the remote electronic device
is at least one of a smartphone, a tablet and a mobile
computer.
8. A method of monitoring a pump system comprising: detecting a
value, the value representing at least one of a water level, a low
battery level, a battery fault, and a pump fault; transmitting a
notification based on the value to a remote electronic device via
an internet connection; and transmitting a notification based on
the value to the remote electronic device via a direct wireless
connection.
9. The method of claim 8 further comprising detecting access to the
internet.
10. The method of claim 8 further comprising pairing the pump
system to the remote electronic device.
11. The method of claim 10, wherein pairing the pump system to the
remote electronic device is done in response to detecting the
pressing of a button.
12. A method for maintaining communication with a pump comprising:
providing a pump having a controller with a communication circuit
for communicating with a remote electronic device over a primary
communication network and over a secondary communication network
when the primary communication network is not available;
communicating via the controller and the remote electronic device
over the primary communication network when the primary
communication network is available; and communicating via the
controller and the remote electronic device over the secondary
communication network when the primary communication network is not
available.
13. The method of claim 12 wherein the primary communication
network comprises a wireless LAN having a router and the secondary
communication network comprises a software enabled access point
(SoftAP) or virtual router network and the method further
comprises: communicating via the controller and the remote
electronic device over the wireless LAN when the wireless LAN is
available; and communicating via the controller and the remote
electronic device over the SoftAP or virtual router network when
the wireless LAN is not available.
14. The method of claim 13 wherein the SoftAP or virtual router
network is formed by the controller serving as a wireless hotspot
and communicating via the controller and the remote electronic
device over the SoftAP or virtual router network when the wireless
LAN is not available comprises connecting the pump controller as a
client of the wireless hotspot.
15. A wireless communication module for a pump comprising: a
computer readable medium for storing network information; a
wireless transmitter; a wireless receiver; an input; and a
processing element adapted to receive the network information from
the computer readable medium and operate the wireless transmitter
and receiver to connect to a wireless network, the processing
element further adapted to operate the wireless transmitter and
receiver to form a hot spot in response to actuation of the
input.
16. The wireless communication module of claim 15 wherein the
wireless transmitter and wireless receiver are a wireless
transceiver.
17. The wireless communication module of claim 15 wherein the
wireless transmitter and wireless receiver are a WiFi module.
18. The wireless communication module of claim 15 wherein the input
is a button.
19. The wireless communication module of claim 15 wherein the
processing element is further configured to transmit commands to a
pump control unit.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 62/433,772, filed Dec. 13, 2016, and U.S.
Provisional Application No. 62/597,407, filed Dec. 11, 2017, both
of which are hereby incorporated herein by reference in their
entirety.
FIELD OF TECHNOLOGY
[0002] The present disclosure generally describes a pump
communication circuit or module, a pump system using same and
methods relating thereto. More specifically, the present disclosure
describes pump systems that have a secondary or redundant
communication method, sump pumps that integrate a backup battery
powered pumping system and a controller that provides status
notification options via the redundant communication setup, as well
as related methods.
BACKGROUND
[0003] Sumps are low pits or basins designed to collects
undesirable liquids such as water around the foundation of a home.
Water that seeps into the home from the outside can flow into the
sump to prevent water from spreading throughout the home. If too
much water seeps into the sump, a sump pump can be employed to move
the water from the sump to a location outside the house.
[0004] A typical electric basement sump pump includes a pump to
remove water from the sump basin, and various switches and related
components that turn the pump on and off when appropriate, based on
the water levels in the sump. Electric sump pumps are generally
powered via an AC power source that plugs into a home's AC power
supply.
[0005] Sump pump systems can also be equipped with audible alarm
and/or user notification systems that transmit messages via text,
e-mail, or a phone call to a user in the event of pump malfunction,
power outage, or high water (flooding) conditions. Unfortunately,
these systems are prone to fail during the most critical times,
such as when line power (or mains power) is lost. Thus, a need
exists for pump components, systems and methods that address this
issue.
SUMMARY
[0006] The present disclosure describes a pump communication
circuit or module that allows for redundant communication, sump
pumps that integrate a backup powered sump pump system into a
primary powered sump pump and utilize such a communication circuit
or module and methods relating to same. The present disclosure also
describes sump pumps that integrate control and notification
systems that determine when to activate the backup DC powered sump
pump system, and notify home owners regarding the operating status
of the integrated pumping system. In addition to various exemplary
embodiments, the present disclosure further covers methods related
to the aforesaid embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Described herein are embodiments of systems, methods and
apparatus for addressing shortcomings of known sump pumps.
[0008] This description includes drawings, wherein:
[0009] FIG. 1A shows an isometric view of an example tandem sump
pump assembly described herein.
[0010] FIGS. 1B and 1C show front and rear elevation views,
respectively, of the tandem sump pump assembly of FIG. 1.
[0011] FIGS. 1D and 1E show right and left elevation views,
respectively, of the tandem sump pump assembly of FIG. 1.
[0012] FIGS. 1F and 1G show top and bottom plan views,
respectively, of the tandem sump pump assembly of FIG. 1.
[0013] FIG. 2A shows an example of a tandem sump pump assembly
connected to a discharge pipe with an integrated control/power
module.
[0014] FIG. 2B is an up close view of the tandem sump pump assembly
of FIG. 2A.
[0015] FIG. 3 is a diagram demonstrating various functionality of
an integrated sump pump control and battery charging system
described herein.
[0016] FIGS. 4A-B are sketches showing an example of a sump pump in
a sump pit with a pressure tube.
[0017] FIGS. 5A-B show examples of a warning notification and
communication system described herein.
[0018] FIG. 6 shows a top view of an exemplary configuration of a
twin volute component of a tandem sump pump assembly.
[0019] FIG. 7 is an example of a conventional DC powered backup
sump pump.
[0020] FIG. 8 is a schematic diagram of an example control system
for a tandem sump pump system described herein.
[0021] FIG. 9 is a schematic diagram of a dual processor redundant
backup system for a sump pump system described herein.
[0022] FIG. 10 is a schematic diagram of an alternate example of a
redundant controller system as described herein.
[0023] FIG. 11A is a schematic drawing of a redundant control
system for a dual sump pump arrangement utilizing a processor and a
software-free relay controller in accordance with examples
described herein.
[0024] FIG. 11B is a more detailed schematic of a redundant control
system for a dual sump pump arrangement utilizing a processor and a
dual switch software-free relay controller in accordance with
examples described herein.
[0025] FIG. 11C is a sketch of a redundant switch used in
accordance with examples of redundant control systems described
herein.
[0026] FIG. 12 is a schematic drawing of a system that allows two
separate pumping systems to communicate with one another in
accordance with examples described herein.
[0027] FIGS. 13A-G show various views of an alternate exemplary
tandem sump pump assembly with cross-over piping and associated
check valves extended at a height above the sump pumps and/or above
the sump pit in order to simplify service of same in accordance
with examples described herein.
[0028] FIG. 14 is a bottom view of an exemplary embodiment of a
sump pump assembly where the two sump pumps are of different sizes
in accordance with examples described herein.
[0029] FIG. 15 shows an example of a tandem sump pump system that
utilizes two separate discharge lines without a crossover pipe in
accordance with examples described herein.
[0030] FIG. 16A shows an exemplary sump pump assembly with a
bracket that cuffs the two pumps together in accordance with
examples described herein.
[0031] FIG. 16B shows the bracket of the assembly of FIG. 16A
having a bridged configuration to support a pressure tube.
[0032] FIG. 17 shows an example of a flat, or planar bracket that
could be used in accordance with a sump pump assembly described
herein.
[0033] FIG. 18 shows an example of a pressure tube housing used in
accordance with examples of sump pump systems described herein.
[0034] FIG. 19A shows an example of a sump pump system utilizing
check valves for demonstrative purposes.
[0035] FIG. 19B shows an example of a sump pump system without
check valves for demonstrative purposes.
[0036] FIG. 20 shows an example of a sump pump assembly utilizing
separate check valves for each pump in accordance with examples
described herein.
[0037] FIG. 21 shows an example of a dual sump pump system with an
isolation valve in accordance with aspects described herein.
[0038] FIGS. 22A and 22B show a cross section of an isolation check
valve in various states of operation in accordance with examples
described herein.
[0039] FIG. 23 shows a cross section of one example of an isolation
valve described herein.
[0040] FIG. 24A shows another example of an isolation valve, and
FIGS. 24B-D show cross sections of the isolation valve of FIG. 24A
in various states of operation accordance with other examples
described herein.
[0041] FIG. 25A shows an example of a sump pump system with a
redundant high water switch in accordance with aspects described
herein.
[0042] FIG. 25B shows the sump pump system of FIG. 25A, with a
cover of the high water switch removed to show the internal
components of the high water switch.
[0043] FIG. 26 shows a configuration of a dual pump assembly
incorporating a strap handle in addition to other features
described in the examples presented herein.
[0044] FIG. 27A shows a dual pump assembly with an air switch and a
one-piece discharge pipe in accordance with examples described
herein. FIG. 27B shows a bracket of the dual pump assembly of FIG.
27A in more detail and separate from the assembly.
[0045] FIG. 28 shows a remote display panel for a pumping system
that provides system status and water level information in
accordance with examples described herein.
[0046] FIG. 29A is a top view of an integrated pump controller and
battery management system in accordance with examples described
herein.
[0047] FIG. 29B is a rear view of the integrated pump controller
and battery management system of FIG. 29A.
[0048] FIGS. 30A and B show an example of a tilt switch utilizing
an accelerometer in accordance with examples described in this
application.
[0049] FIG. 31 shows an example pumping system employing a sump
pump and the tilt switch of FIGS. 30A and B.
[0050] FIGS. 32A and 32B show various views of an integrated pump
controller and battery management system in accordance with
examples described herein.
[0051] FIG. 33 shows a multi-pump system having a connector for
connecting two pumps in accordance with examples described
herein.
[0052] FIG. 34A shows a simplified network diagram over which a
pump communicates in a first state.
[0053] FIG. 34B shows a simplified network diagram over which a
pump communicates in a second state.
[0054] FIG. 35A is an exemplary flow chart illustrating setup or
installation of the pump communication system of FIGS. 34A-34B.
[0055] FIG. 35B is an exemplary flow chart illustrating operation
of the pump communication system of FIGS. 34A-34B after setup.
[0056] FIGS. 36A-36Q are screenshots of a software application
interface for operating and/or communicating with a pump system
described herein, with FIGS. 36A-36F relating to initial
installation or setup of the system by a professional installer,
FIGS. 36G-36H relating to setup and registration by a home owner,
FIGS. 36I-36K relating to normal operation of the system with a
Wi-Fi internet connection present, FIGS. 36L-36O relating to
operation of the system when Wi-Fi internet connection is lost,
FIG. 36P relating to a notice provided when regular Wi-Fi internet
is available while in Soft AP direct connection mode and FIG. 36Q
illustrating an example of what the screen display would look like
if regular Wi-Fi internet is available but the AC pump went offline
for some reason.
[0057] FIG. 37A illustrates a pump system having a wireless
communication module and a remote display.
[0058] FIG. 37B illustrates the wireless communication module of
the pump system of FIG. 37A.
[0059] Corresponding reference characters in the attached drawings
indicate corresponding components throughout the several views of
the drawings. In addition, elements in the figures are illustrated
for simplicity and clarity and have not necessarily been drawn to
scale. For example, the dimensions of some of the elements in the
figures may be exaggerated relative to other elements to help to
improve understanding of various embodiments. Also, common but
well-understood elements that are useful or necessary in a
commercially feasible embodiment are often not depicted or
described in order to facilitate a less obstructed view of the
illustrated elements and a more concise disclosure.
DETAILED DESCRIPTION
[0060] Sump pumps are often most useful during storms. That is
because storms bring in large amounts of water that can lead to
flooding. However, storms can also result in a home losing power.
In such a situation, an AC powered sump pump will be unable to
operate. Accordingly, for security purposes, home owners also
install a battery back-up system that can supply power to a DC pump
to remove water from the sump basin in the event of an AC power
outage or primary pump malfunction.
[0061] Such a battery back-up system may include a DC powered pump
to remove water from the sump basin, float level switches and
related components to turn the pump on & off based on water
levels, and a 12-volt DC battery with a charging system and related
electrical connections. An example of such a conventional pump 700
is shown in FIG. 7.
[0062] Combining a primary AC powered sump pump system with a
separate backup DC powered sump pump system can present several
drawbacks. For example, as the complexity of these primary &
back-up pump systems increase, the overall reliability can be
impacted by the number of switches and electrical connections.
[0063] Additionally, the ability of the system to transmit messages
during power outages can be compromised or limited in function, as
the notification systems generally rely on home functionality
(e.g., land line circuits) that are also inoperable during power
outages. Thus, these systems cannot take advantage of the latest
communication technologies.
[0064] Further, sump systems with two pumps and multiple float
switches are often too large to fit into the smaller diameter sump
pits found in older homes. As a result, such homes with smaller
sump pits are not able to take advantage of the benefits of a
conventional backup DC sump pump system or require homeowners to
purchase items to help place the pumps in a staggered manner in the
sump pit which is not convenient.
[0065] The present disclosure describes sump pumps that integrate a
backup DC powered sump pump system into a primary AC powered sump
pump. The present disclosure also describes sump pumps that
integrate control and notification systems that determine when to
activate the backup DC powered sump pump system, and notify home
owners regarding the operating status of the integrated pumping
system. Still further, the present disclosure also describes a
redundant pump communication system that allows a home owner or
pump user to continue to have communication with a pump even when
the primary means of communication is not available (e.g., such as
when a storm knocks out power to a home disrupting its network
operations). For example, a pump communication system is disclosed
that utilizes a remote electronic device's own wireless access
point technology to form a hotspot that the pump communication
module can tether to so that the pump is capable of communicating
even if the primary communication circuit (e.g., a wireless network
circuit) is down due to a problem with the primary communication
network or its components (e.g., router, modem, etc.). In this way,
the system forms a secondary or redundant communication technique
for the pump to use to maintain communication while the primary
communication technique is unavailable.
[0066] FIG. 1A shows an isometric view of an example tandem sump
pump assembly 100. As shown in the Figure, the sump pump assembly
100 includes a first pump 120 and a second pump 130. FIGS. 1B-G
show front, rear, right, left, top, and bottom views of the tandem
pump assembly 100, respectively.
[0067] In the form shown, the first pump 120 is a primary pump
powered via an AC power supply 102 and the second pump 130 is a
backup pump powered by a DC power supply 104, such as a battery.
However, it should be understood that in alternate embodiments the
pumps can be setup in any desired configuration. For example, in
some embodiments, pump 130 could be the primary AC pump and pump
120 could be the backup DC pump. In other embodiments, both pumps
120 and 130 could be AC pumps powered via an AC power supply, or DC
pumps powered by a DC power supply. In still other embodiments,
pumps 120, 130 could be any combination of AC/DC pumps desired.
[0068] Turning back to the embodiment illustrated in FIGS. 1A-G, in
a preferred form, the system 100 includes two separate check valves
161 and 162 that inhibit backflow into each of the separate pumps,
but that ultimately discharge into a common discharge outlet 160.
In addition, the pump assembly comprises a twin volute 110, that
serves as the volute for both pumps 120, 130 of the assembly. In
some examples, the twin volute 110 comprises two separate volutes
111 and 112 (e.g., one for each pump) that are not in fluid
communication with one another as shown in FIG. 1G. In some
examples, the twin volutes 111 and 112 can be arranged in a space
saving and attached configuration as shown in FIG. 1G. In this
form, the volutes 111, 112 are shown to have a "yin-yang"
configuration (or semi-yin-yang configuration), which allows the
pump to save space. This space saving configuration allows the
assembly 100 to fit into smaller sump pits. In some examples the
volutes 111 and 112 may be similar or even identical in size. In
other examples, one volute (e.g., volute 112) may be larger or even
significantly larger than the other as will be discussed further
below regarding alternate embodiments.
[0069] While the embodiment shown in FIGS. 1A-G illustrate the
volutes being connected to one another to make the tandem system
100 easier to place in the sump pit together as a stable assembly,
it should be understood that in alternate embodiments the pumps and
pump components may be configured so as not to be connected to one
another except by the common discharge piping to simplify servicing
so that one pump may be removed and worked on or replaced without
requiring removal of the other pump, if desired (which will also be
discussed further below regarding alternate embodiments).
[0070] Turning back to the embodiment illustrated, FIG. 1G shows
the twin volute 110 as two separate volutes 111 and 112 that are
separable from one another, but interconnected or connected to one
another via a fastener or connector. That is, they are not formed
as part of a single piece, but are instead held together by way of
a fastener or connector. In alternate forms, the volutes may be
held together with assembly 100 via attachment to the pump assembly
100 (e.g., via attachment to their respective pumps which are then
connected to one another via the common discharge piping). Pads
115a-f on the bottom surface of the twin volute can help support
the stability of the system 100. In some embodiments, however, the
twin volute 110 can be a single piece that may be formed, for
example, from a single molded or cast material. FIG. 6 shows an
example of a twin volute 610 formed as a single component.
[0071] In some examples, the independent volutes 111/611 and
112/612 of the twin volute 110/610 are not in fluid communication,
even if the volutes are formed as a single component, as shown in
FIG. 6. That is, they are discrete or individual volute chambers or
fluid passages with no fluid path connecting the two volute
chambers or fluid passages. In other examples, however, the twin
volute 110/610 may include a single or common volute chamber or
fluid passage such that the volute for each of pumps 120 and 130
are one in the same or at least in fluid communication with one
another.
[0072] Referring again to FIGS. 1A-G, the assembly 100 includes an
integrated handle 140 that allows for both pumps to be carried
together, and lowered into a sump or a pit in a basement. This
integrated handle 140 allows for easy installation or simplified
out-of-box drop-in setup. In a preferred form, the handle 140 works
together with the common discharge piping to interconnect the pumps
120, 130 so that the system can easily be installed or removed as
one assembly.
[0073] As mentioned above, in a preferred form, the assembly 100
has a single discharge outlet 160, such that each of the first pump
120 and the second pump 130 pump fluid toward the common discharge
outlet 160. The discharge outlet 160 can connect to a discharge
pipe via a check valve. Because the assembly utilizes one discharge
outlet for two pumping units, the assembly can be installed in a
quicker manner. That is, an installer need only connect a discharge
pipe to a single outlet, which can save considerable time in the
installation process. Each pump 120 and 130 can pump fluid toward
the discharge outlet 160 through respective check valves 161 and
162, which are connected via cross-over piping 165. Thus, this
discharge piping helps interconnect the pumps 120, 130 to one
another so that they may be placed as an interconnected
assembly.
[0074] In some aspects, the discharge outlet 160, cross-over piping
165, and check valves 161 and 162 can be moved higher up above the
sump pumps 120 and 130. For example, some embodiments may utilize a
length of tube or pipe such that check valves 161, 162, and
discharge outlet 160 are raised higher, so that they extend out of
the sump pit. FIGS. 13A-G present an example of a tandem sump pump
assembly 1300 with cross-over pipe 1365 extended at a height above
the sump pumps 1320 and 1330 and above the sump pit. For example,
discharge outlet 1360 and the two check valves 1361 and 1362 are
elevated far above the assembly and connected via a crossover 1365
pipe significantly above the sump pumps 1320 and 1330 when compared
with the embodiment of FIGS. 1A-G. That is, the cross-over pipe
1365, the primary pump check valve 1361, and the secondary pump
check valve 1362 are positioned at a height sufficiently high above
the primary 1320 and secondary pumps 1330 so that when the tandem
sump pump unit 1300 is placed in a sump pit, the primary pump check
valve 1361, and the secondary pump check valve 1362 are accessible
for maintenance and repair without having to enter the sump pit or
remove the tandem sump pump unit from the sump pit. In this manner,
an operator can effectively disconnect one pump from outside the
sump without having to turn the system off, as the check valves
will be more readily within reach. That is, within reach from
outside of the sump pit without having to enter the pit, or without
having to remove both pumps from the sump pit. One pump can be thus
replaced and/or repaired while the other pump continues to operate.
That is, one pump can be disconnected from the system and then
pulled up from the sump while the other pump continues to operate.
In such embodiments, the assembly 1300 may employ separate or
dis-connectable volutes rather than the common volute 1310
described above.
[0075] FIG. 15 provides another example of a tandem sump pump
system 1500 that utilizes two separate discharge lines 1660a and
1660b without a crossover pipe. That is, the pump system 1500
includes a first pump 1520 and a second pump 1530 that each utilize
a separate discharge line 1560a and 1560b, respectively. In this
example, unlike that of FIGS. 13A-G, no crossover pipe connects the
primary check valve 1561 and the secondary check valve 1562 to
direct the pumped fluid to a common discharge line. Instead, each
pump 1520 and 1530 pumps toward its own discharge outlet. This dual
outlet configuration provides redundancy advantages in that, if one
discharge line becomes clogged or blocked by debris, vermin, or the
like, the other discharge outlet will remain operational. Further,
employing separate discharge lines allows the system to omit the
individual check valves, if desired (e.g., primary check valve 1561
and secondary check valve 1562 can be optional). This can provide
added cost savings and a simplified design. Additionally, using
separate discharge lines as shown in FIG. 15 can reduce system
pressure drop, which allows the pumps to operate at a higher flow
rate. In some examples, the check valves 1562 and 1561 (along with
other components) can be made from stainless steel. In other
examples, the check valves can be made from a plastic material or
other metals.
[0076] In FIGS. 1A-G the sump pumps 120 and 130 are generally
depicted as being the same size. It is contemplated that in some
embodiments the sump pumps can be different in size, shape, or
operation. FIG. 14 is a bottom view of an example sump pump
assembly 1400 with such a configuration. That is, the first sump
pump volute 1411 (which can be, for example, a primary pump, such
as an AC powered pump) may be larger than the second sump pump
volute 1412 (which can be, for example, a backup pump, such as a DC
powered pump). It should be understood that smaller volutes are
typically associated with smaller pumps and smaller pump housings.
Accordingly, it should be understood that the assembly 1400 of FIG.
14 could include two pumps of different sizes.
[0077] FIG. 2A shows an example of a tandem sump pump assembly 200
connected to a discharge pipe 270 via check valves 261, 262 (262 is
not shown, but is similar in type and location to check valve 162).
FIG. 2A shows an expanded view that includes an integrated
control/power module 280. FIG. 2B is an up close view of the tandem
sump pump assembly of FIG. 2A. As shown, a rubber coupling connects
the discharge outlet 250 of the assembly 200 to the discharge pipe
270, and is secured via conventional hose clamps. This
configuration allows the assembly 200 to be placed in the sump pit
and then secured to existing plumbing if needed. However, in
alternate embodiments, the discharge piping may be configured in a
variety of different ways (see an exemplary embodiment of this in
FIG. 13A which will be discussed later).
[0078] As shown in FIG. 2A, the system also includes a
control/power system 280. In some examples the control/power system
will be an integrated module, as shown in the embodiment of FIG.
2A, where the control circuit and power circuit are included as a
part of the same component. In other forms, the control circuit and
power circuit may be integrated into a controller further removed
from the sump pit area, such as the control unit 510 illustrated in
FIGS. 5A-B. This integrated design moves the pump motor switch
operation "out of the water", thereby increasing reliability. That
is, because the sump control system enclosure can also accommodate
the battery charging electronics, the charging components are moved
away from the harsh environment of the battery box and into an area
more convenient for viewing & operation by the home owner. This
can be useful, for example, for sealed sump units with Radon
abatement systems. The lower profile of the pump embodiment of
FIGS. 1A-G (as compared to the high crossover/easy servicing
embodiment of FIGS. 13A-G) may also be more desirable in such
sealed sump units because of the ability to contain the tandem
assembly within the sealed pit.
[0079] In other embodiments, the power controller and the
communication module may be separate modules, so that either module
can be removed, uninstalled, replaced or otherwise separately
provided from the other module. For example, in FIGS. 5A-B, a
system is illustrated having separate control and communication
modules. By offering a separate modular arrangement, the system can
take advantage of improvements in power and/or communication
technologies, without requiring replacement of the other
power/communication equipment. Moreover, the interchangeability of
the power and control systems allows the systems to be adapted for
different pumps and equipment that may operate on different power
configurations. For example, with this configuration the systems
can be adapted to be used with 10 amp pumping systems, or 4 amp
pumping systems, or other pumping systems having differing
operating parameters or employing various different electrical
configurations. In yet other forms, the system may be configured
with separate pump control, power control and communications
modules so that any of these modules may be repaired, replaced or
updated without requiring change to the other modules.
[0080] Returning to the embodiment of FIGS. 2A-B, the integrated
control/power system 280 can include a central control system,
(also referred to as a controller) in electrical communication with
the sump pump system (e.g., systems 100 or 200 of FIGS. 1A-B and
2A-B). That is, the controller can be in electrical communication
with a primary sump pump that is powered by an AC power supply and
a backup sump pump that is powered by a DC power supply. Via the
controller, the control/power system 280 can be configured to
control operation among the primary sump pump and the backup sump
pump. Again, as mentioned above, the system could be setup to use
two DC pumps or two AC pumps as desired, however, in a preferred
form, the system will be configured with at least one DC pump,
which would be needed for power outages as discussed above.
[0081] The control/power system 280 also includes a charging module
configured to charge the DC power supply and a battery that
provides power to the pump system in the event of a power outage to
the home. The charging module can operate to charge the battery
when AC power is on to ensure that the battery is fully charged in
the event of a power outage or other problem with the AC power
source.
[0082] In some forms, the controller can serve as the controller
for the entire sump pump system. In other forms, different
controllers may be used for different responsibilities or,
alternatively, may be setup in a redundant manner as will be
discussed further below. In still other forms, other fallback
designs may be used to help the system operate at least in a
minimal capacity even if the controller fails. These will be
discussed further below with respect to other embodiments.
[0083] FIG. 3 is a diagram demonstrating various functionality of
an integrated sump pump control and battery charging system 300. In
some examples, the system 300 is connected to an AC power source
310 (e.g., a 120V power outlet) and, thus, includes an AC input
(e.g., a power cord and plug, etc.), a DC power source 320 (e.g., a
battery or battery hookup), or a combination of both. Fluid level
inputs can be supplied by single or multiple input mechanisms such
as float switches 330, relative displacement (tilt) switches,
pneumatic pressure switches 340 (e.g., probe tubes) or the like. In
the form illustrated, the auxiliary float switch 330 is meant to
connect to a high water float switch or water level sensor to
identify a high water or flood condition via display 355. In this
way, the auxiliary float switch 330 serves as a redundant fluid
level sensor to back up the pneumatic pressure tube sensor 340. The
system 300 can also include an audible alarm 360 that can be used
to produce a signal or warning. For example, audible alarm 360 may
include a speaker arrangement, a buzzer, a siren, a beeping device,
or the like. In some forms, the controller or system 300 further
includes an output to connect to a home security system to trigger
an alarm or notification condition via the home security
system.
[0084] In some forms, the system 300 may include an interface 350
that displays information pertaining to the operating status of the
system. For example, the interface 350 may display information
pertaining to the water level 351, the battery status 352, and the
operation status of the backup pump 353 or main pump 354. The
interface 350 may also include high water warning icons 355,
battery fault icons 356, or control switches that execute
functionality, like a system test switch 357 (e.g., that activates
a system test protocol) and a buzzer switch 358 (e.g., that shuts
off or mutes a buzzer). In the form illustrated, the visual
displays 351, 355, 353, 356 and 354 coincide with the inputs 340,
330, 370, 320 and 380, respectively, and utilize colors to relay
information regarding system status or water status. For example,
green colors appearing in conjunction with the water level sensor
351, back-up pump indicator 353, battery indicator 356, and main
pump indicator 354 indicate the system is running properly.
Conversely, red colors appearing in conjunction with water level
sensor 351, high water indicator 355 and battery fault and state
indicator 356 indicate a potential or current problem with the
system (e.g., low battery, no battery, etc.) or undesirable high
water level situation. In the form illustrated, the system 300 is
setup modularly so that system 300 serves as the pump controller
and nearby notification module, but is also connected to a
communications or remote notification module to provide further
notification to remote locations such as remote user locations via
an analog or digital auto dialer unit, a cellular or digital
notification unit, etc. FIG. 3 depicts some exemplary data that may
be communicated between the communications module and system or
controller 300 such as AC system power status, water level, alarm
conditions, DC system power status, battery state, pump operation,
pump cycle count, system failures and remote diagnostic or testing
features.
[0085] Some examples described herein may employ a controller that
monitors and assesses battery state of health, and/or battery state
of charge properties. Conventional battery test methods for pumping
devices often involve discharging, or at least partially
discharging the battery. But this can cause problems, in
particular, with how power or heat generated during the test is
dissipated. Accordingly, certain aspects described herein may
employ battery testing and assessment techniques that use
conductance measurements. Conductance describes the ability of a
battery to conduct current. At low frequencies, the conductance of
a battery is an indicator of battery state-of-health showing a
linear correlation with a battery's timed-discharge capacity.
Accordingly, information obtained from the conductance test can be
used as a predictor of battery end-of-life. In one aspect, a
controller may be equipped to utilize similar operating software
that is used to test equipment related to other industries, such as
automotive equipment, and may also use advanced monitoring systems
that are associated with stationary power applications. That is,
the testing algorithms used to monitor these other types of
equipment could be incorporated into a control board of the
controller. In this manner, the present controller can use
conductance testing of the battery to determine state of health
and/or state of charge, which has not been utilized in conventional
battery back-up sump systems.
[0086] The present disclosure also describes warning and
communication systems used in connection with pump systems. FIGS.
5A-B show examples of a warning notification and communication
system. FIG. 5A shows an expanded view that includes a system
controller such as notification module 510 and a communication
module 520, and FIG. 5B shows a close up view of the notification
module 510. As shown, the notification module 510 comprises a
series of LED lights 512n that light up to indicate warnings or
other information. For example, the LED lights 512 can represent
operation of the backup pump, operation of the primary pump, a
water level warning, a low battery level warning, a battery fault
warning, etc. In some examples, the LEDs 512 can include a
plurality of lights that sequentially light up to indicate an
amount of water or fluid in the sump pit. For example, the LEDs 512
can illuminate in a way to indicate a "low" "medium" and "high"
water level so that a quick glance at the display immediately
indicates the amount of water in the sump pit (e.g., fewer
illuminated LEDs means low fluid level, intermediate number of
illuminated LEDs means higher fluid level, many illuminated LEDs
means high fluid level, all on and strobing to indicate too high of
a fluid level or too high of a level for too long of a period of
time, etc.). The notification module 510 can also be equipped with
a speaker or other audible equipment to generate sounds or audible
alarms in certain situations. For example, the notification module
can be configured to sound a buzzer or alarm when the water level
is rising beyond a predetermined threshold or when the fluid level
remains at or above a threshold level for too long a period of
time, etc.
[0087] The communication module 520 can be configured to
communicate notifications via a number of wireless or wired
technologies. For example, the communication module 520 can be
configured to send text alerts via a cellular network. Additionally
and/or alternatively, the communication module can be configured to
send signals via a network, such as the internet, via a hard wired
or a Wi-Fi connection, a land-line connection, or another approach.
In this manner, the communication module 520 can communicate and/or
interact with a remote device, such as a smart phone, a tablet, a
laptop or other computer.
[0088] In some embodiments, the module 280 could allow battery
back-up to power the communication module 520 and other modules or
components (e.g., an electronics module) during an AC power outage
so that notifications, the application services described herein,
and other features (e.g. cellular or digital notifications, such as
text notifications, etc.) remain functional and/or operational.
[0089] FIG. 8 is a schematic diagram of an example control system
800 for any of the tandem sump pump systems described herein. The
control system 800 (which can be the same as or similar to battery
charging and control system 300 described above with respect to
FIG. 3) includes a controller, such as microprocessor 810, in
connection with a variety of equipment, sensors, and outputs. The
system 800 includes an AC pump 820 represented by a motor symbol,
which connects to an AC power supply 822 (e.g., a 110 V AC power
supply) and can be used to operate one pump of a tandem sump pump
system.
[0090] A current sensor 824 monitors the current drawn by the AC
pump 820, and communicates with the microprocessor 810. In this
manner, when current drawn by the pump 820 (e.g., by the pump
motor) is above or below a threshold (e.g., signifying that the
pump may be having issues), the microprocessor can take any of a
number of pre-prescribed actions. For example, detection of low
current usage may indicate the pump has no more water to remove
and, thus, the controller may shut down the pump to avoid motor
burnout. Detection of high current usage may indicate the pump is
jammed and, thus, the controller may cycle the pump motor on and
off to try and dislodge whatever is causing the bind or may shutoff
the motor and trigger a notification of an error. The
microprocessor may operate any of the number of outputs, such as
the audio alarm 870, LED lights 880, or other functionality (such
as sending a communication via the communication module) to
indicate or relay such errors.
[0091] In a preferred form, the system 800 will be configured with
a first switch for operating the primary pump and a second switch
for operating the backup pump. For example, switch 826 can be used
to control the supply of AC power to the system 800. In some
examples, switch 826 can include any AC switch, such as a solid
state relay (SSR) (e.g., an opto-triac or triac and alternistor,
etc.). In the form illustrated, the switch 826 is an opto-triac
coupler, which can be employed to block high voltage and voltage
transients from the AC portion of the circuitry to other areas of
the system 800, such as the DC portions of the circuitry. In this
manner, the switch can help assure that a surge in the AC part of
the system 800 will not disrupt or destroy the other parts of the
system 800. In other examples, the switch 826 can include a DC
switch if the circuit includes a transformer (e.g., an isolation
transformer) and the pump being operated is instead a DC pump.
[0092] Returning back to FIG. 8, the system 800 also includes a DC
pump 830 (again represented by a DC motor symbol) which can be used
to operate a second pump of the tandem pump system. The DC pump 830
receives DC power from either a DC battery 834 (e.g., a 12 V
battery), a battery charger 832 (e.g., a 12 V battery charger), or
a combination thereof. For example, the system may be setup to
cycle usage of the pumps between the first and second pump 820, 830
so that one does not wear out before the other. Thus, when the DC
pump 830 is to be used, the battery charger 832 may simply be used
as an AC-DC power adaptor to step the AC power supply down to DC
power to operate the DC pump 830 without requiring power to be
supplied by battery 834 so that the battery remains fully charged
for use during AC power outage situations. The battery charger 832
is in communication with the AC power supply 822 and the battery
834, thereby ensuring that the battery 834 maintains a charge in
the event of an AC power outage. The DC portion of the circuit also
includes a current sensor 838 that monitors current drawn by the DC
pump 830, and a switch 839 that opens and/or closes the DC portion
of the circuit. In this manner, the switch 839 can control the
supply of DC power to the DC pump 830 and the controller 800 can
perform similar tasks to those discussed above with respect to the
AC motor when detecting too little or too much current draw (e.g.,
shut off the pump if too little current is drawn indicating
insufficient fluid presence, cycle on and off the pump to attempt
to dislodge a blockage leading to too much current being drawn by
the motor, turning off the motor if too much current is drawn by
the DC motor, etc.).
[0093] The system 800 also includes a voltage supply 836 that
supplies power from the DC battery 834 to the microprocessor 810 or
as mentioned alternatively above from the battery charger 832
serving as an AC-DC adapter. With this configuration, the
microprocessor 810 can still operate in the event of an AC power
outage by drawing power from battery 834. Another current sensor
842 monitors the current drawn by the battery 834 to indicate to
the controller 810 if a problem has occurred with the battery 834
(e.g., too low or high of a current being provided, etc.). In other
aspects current sensors can be associated with other components of
the system (e.g., the microprocessor 810) to monitor the current
that the components are drawing and further notifying of other
problems or errors in circuit or component operation.
[0094] The system 800 includes a push-button 840, which can be
pressed, for example, by a user to activate one of a number of
system tests. For example, the push-button 840 can be pressed to
determine whether the battery 834 is sufficiently charged. The
push-button 840 can also be used for one or more other functions,
including, for example, to silence an alarm, deactivate a
notification, re-set warning signals, start a test cycle, or the
like.
[0095] The microprocessor 810 also operates in connection with a
number of outputs. For example, the microprocessor 810 may
communicate data and/or information via a data output 850. The data
output 850 can include, a communication device that transmits text
alerts, notifications, or other communications to a user via a
remote device.
[0096] In some embodiments, the microprocessor may also include an
auxiliary signal output 860, which can be another auxiliary alarm,
such as a home security system and/or a communication/texting
protocol system. The auxiliary signal output 860 can include a
switch 862 that allows the auxiliary output 860 to be activated or
deactivated as appropriate.
[0097] The microprocessor 810 can communicate with an audio alarm
870 that activates an audio signal in response to certain events,
or a series of lights 880 (e.g., LEDs) that can execute various
lighting sequences in response to certain events as described
herein.
[0098] In some embodiments the microprocessor 810 is also in
communication with a number of additional switches and sensors,
including, for example, a float sensor 890, and a pressure sensor
895.
[0099] The system of FIG. 8 demonstrates various examples of
redundancy and/or backup to ensure proper operation of the system
in the event of failure of some of the components. For example, the
system 800 includes redundant pumps 820 and 830, redundant battery
sensors 836 and 842 for determining battery performance, redundant
power supplies 822, 834, and redundant water level sensors 895,
890. FIG. 8 does not provide examples of controller and/or
microprocessor redundancy. However, some examples described herein
provide systems and/or methods to provide redundancy for a
controller such that the system can continue to function in the
event that the controller itself fails. This controller redundancy
can be provided in a variety of different levels, including a dual
processor level that ensures full operation of many or even all of
the functionality of the system even when a primary controller
fails. Alternatively, simpler or less expensive systems can also be
provided that ensure operation of the pumps in the event of a
controller failure, but without providing all of the other premium
features of a more expensive dual processor system.
[0100] FIGS. 9-12 present examples of pumps and related systems
that offer redundancy. For example, some systems include two pumps
operated, managed, or otherwise controlled by a dual processor
(e.g., a dual microprocessor). The dual processor can be configured
so that one portion of the processor operates a first pump (e.g., a
primary pump or an A/C powered pump) while a second portion of the
processor operates a second pump (e.g., a backup pump or a D/C
powered pump). In the event that one processor or processor portion
goes down, the dual processor system can configure control so that
the other operating processor assumes control of both pumps. In
this manner, the system can continue to operate on all levels even
in the event of a failure to one processor. In some examples, the
dual processor can be, or can include two separate processors, with
each processor portion comprising a separate processor device. In
other examples, the dual processor is one chip or board configured
to operate as a dual processor.
[0101] FIG. 9 is a schematic diagram of a redundant control system
900 for a dual sump pump arrangement utilizing dual controllers,
such as processors 910 and 911. In this embodiment, a first
microprocessor 910 can be configured to control operation of a
first pump, for example, an AC powered pump 920. The second
microprocessor 911 can be configured to control a second pump, for
example, a DC powered pump 930. Each microprocessor can be in
communication with various sensors, and other audio/video alarms or
functionality. Moreover, in the event that one microprocessor
fails, the other microprocessor can assume the functionality of the
first microprocessor. For example, if the first microprocessor 910
fails, the second microprocessor 911 can assume control of the
primary pump 920, while also assuming the control of the signaling
and other communication functionality described herein. Likewise,
in the event that the second microprocessor 911 fails, the first
microprocessor 910 can assume control of a backup sump pump 930,
and other related functionality. Moreover, the system may utilize
redundant water level sensors, such as a pressure sensor 940 and a
high water float switch 942, each of which is in communication with
each of the two microprocessors 910 and 911.
[0102] While utilizing a dual processor system such as that
described with respect to FIG. 9, such a system can be more
complicated and expensive. Accordingly, the present disclosure also
describes examples where one processor is a simpler processor than
the other. For example, one processor may be a scaled down or
scaled back version of the other processor (e.g., a simplified
controller) so that in the event of a failure, the simplified
controller can perform some, but not all of the functionality of
the primary processor. In this manner the system may be more cost
effective and easier to operate on account of the simplified
controller, but may still be able to perform the important tasks
(e.g., prevent flooding) in the event of a primary processor
failure so that the system can continue to operate in urgent
situations. In some forms, the power supply for each of the
controllers 910, 911 may be handled separately as well in yet
another example of redundancy. For example, a separate transformer
or step down/rectifier circuit may be used to supply power to the
first controller 910 and the battery may be used to supply power to
the second controller 911. In other forms, however, both may be
powered from the same DC power source (e.g., such as the battery
charger as an AC-DC adapter and, if AC power is not available, from
the battery as discussed above).
[0103] FIG. 10 is a schematic of another example control system
1000 for a tandem sump pump system with redundant controller
features. The control system 1000 includes a microprocessor 1010 in
connection with a variety of equipment, sensors, and outputs,
including a primary pump 1020 (e.g., an AC pump), and a secondary
pump 1030 (e.g., a DC pump).
[0104] Unlike system 900 of FIG. 9 which includes dual controllers
(e.g., processors 910 and 911) that can maintain all or virtually
all of the functionality of the system (e.g., including the
warning, transmission, and monitoring features, etc.) in the event
that one microprocessor or controller fails, the system of FIG. 10
operates on a more efficient basis in the event that microprocessor
1010 fails. As such, the system 1000 may be simpler and more cost
effective, but still allow the pumps 1020 and 1030 to continue to
operate in the event of a failure while the primary microprocessor
1010 or controller is being repaired or replaced. In this manner,
the system 1010 may employ a redundant controller, such as monitor
1001 that communicates, or is in communication with many of the
system components. The monitor 1001 can be configured to
essentially monitor microprocessor 1010 to ensure that it is
operating effectively. When it detects that the microprocessor 1010
is not operating effectively, the monitor 1001 can assume control
of one or both of the primary pump 1020 and backup pump 1030 so
that the essential pumping operations continue to operate as
necessary.
[0105] In some examples, the monitor 1001 can serve as another
microprocessor that performs some of, but less than all of the
functions of the microprocessor 1010. For example, the monitor 1001
may be able to control between operation of the two pumps 1020 and
1030, but not perform any of the alarm or communication
functionality. In other aspects, however, the monitor 1001 performs
only a small number of tasks, sufficient to keep the system 1000
operating efficiently while the microprocessor 1010 undergoes
maintenance. For example, the monitor 1001 may be a simple logic
circuit that includes a logic gate or logic gates (e.g., and/nand
logic gates, or the like). Thus, the monitor 1001 allows the system
1000 to operate minimally, such that only the essential operations
are performed while the other module is replaced and/or repaired.
This control system 1000 provides a less expensive redundant system
that allows the system to "limp home" in the event of a failure,
thereby performing all necessary tasks.
[0106] In still further configurations, a very minimal redundant
controller or system may be used that includes a simple relay
switch without software or processors in the redundant/backup
control. FIG. 11A is a schematic drawing of a redundant control
system 1100 for a dual sump pump arrangement utilizing a processor
1110 and a non-processor or logic based relay controller 1111. The
controller can be a simple switch or a simple relay, without any
software or logic required to operate same (e.g., a software free
controller). The microprocessor based controller 1110 and the
second or redundant controller 1111 can be provided in a single
enclosure as a control unit 1101 or, as will be discussed further
below, be modular to allow for one to operate the system while the
other is serviced (e.g., repaired or replaced). In this manner, the
simple relay second controller 1111 can be wired to assume
management responsibilities for the pumps 1130 and 1120 of the
system in the event that the primary microprocessor controller 1110
fails or malfunctions. In this manner, the pumps will either
operate (be "on") or not (be "off") as controlled by the relay
controller 1111, which can be based on one or more sensors, such as
float sensors and/or pressure sensors. In a preferred form, the
redundant controller 1111 will be capable of operating both the
primary and secondary pumps. However, in alternate forms, the
redundant controller 1111 may only be capable of operating one of
the pumps (e.g., the secondary pump, but not the other).
[0107] FIG. 11B is a more detailed schematic of a redundant control
system 1100a for a dual sump pump arrangement utilizing a processor
and a dual switch software-free relay controller. Here, the simple
relay second controller 1111 is shown in more detail as a dual
redundant switch controller. That is, the second controller
comprises a first redundant switch 1111a that operates the primary,
or AC pump 1120, and a second redundant switch 1111b that operates
the secondary, or DC pump 1130. The redundant switches for the
controller system are two isolated switches with the outputs tied
together and the inputs coming from two independent sources. Each
switch 1111a and 1111b can take on a variety of forms. For example,
in some forms, similar switches may be used for both the primary
and backup pumps. In other forms, an AC switch may utilize
components capable of isolating the DC portion of the circuit from
the AC portion of the circuit (e.g., an opto-triac switch), while
the DC powered switch may include a simple mechanical switch, an
electrical switch such as a transistor (e.g., BJTs, FETs, etc.), or
the like.
[0108] For each switch 1111a and 1111b, the two inputs relate to
the microprocessor 1110 and the high water float switch 1190. If
the microprocessor 1110 fails to operate properly, the float
switch, when it operates, will turn on the switch output which will
activate the AC switch 1111a (e.g., triac switch) or the DC switch
1111b (e.g., FET) to drive one or both pumps 1120, 1130. FIG. 15 is
a sketch showing a simplified circuitry for a switch 1111c that
could be used in such an embodiment. The switch 1511 includes a
motor switch 1103 in circuit with two opto-isolators 1121 and 1122.
However, it should be understood that the actual circuitry may be
different for AC switch 1111a and DC switch 1111b.
[0109] FIG. 12 is a schematic drawing of a system 1200 that allows
two separate pumping systems 1220 and 1230 to communicate with one
another. For example, in one form, the pump systems 1220 and 1230
may communicate with one another when placed proximate each other
via a communication network 1250, which can be a wired connection
or a wireless connection (e.g., radio frequency (RF), infrared
(IR), Bluetooth (BT), Bluetooth Low Energy (BLE), near field
communication (NFC), Wi-Fi, etc.). In the form illustrated, the
systems 1220 and 1230 can communicate with one another and transmit
operational status to a remote display unit 1240, such as a monitor
or other display (e.g., a mobile phone, tablet, PDA, computer, or
other network capable component).
[0110] The control unit 1201 can be configured to have multiple
commination modes and/or communication circuits for transmitting
notifications based on the current availability of power and/or
internet connectivity. As shown in FIG. 34A, when the entire
communication network 3400 is working properly, the control unit
1201 communicates via a wireless communications circuit or module
1215 (e.g., a Wi-Fi module, Bluetooth module, RF module, etc.),
which in turn communicates over the internet via an Internet
Service Provider (ISP) and a network connection device such as a
modem and/or router 1216 to send notifications to the remote
electronic device (e.g., display unit 1240, such as a mobile device
1240a or personal computer 1240b). The Wi-Fi communications module
1215 is a wireless communication circuit communicatively coupled to
the control unit 1201. In some forms, the Wi-Fi communication
module communicates with a local gateway, such as modem and/or
router 1216 in order to transmit and receive information over the
internet. However, in instances of power failure it is not uncommon
to also lose internet access along with line power/mains
electricity.
[0111] Turning to FIG. 34B, the control unit 1201 modifies the
communication process or technique when internet access is lost.
More particularly, when the Wi-Fi communications circuit or module
1215 loses contact with the modem and/or router 1216 a notification
is sent to the Wi-Fi communications circuit or module 1215 and/or
control unit 1201. In some forms, the notification comprises a
cessation in responses received at the control unit 1201 or Wi-Fi
communications circuit or module 1215 from the internet service
provider or modem and/or router 1216 or the remote display unit
1240. When this lack of internet connection is detected, the Wi-Fi
communications circuit or module establishes direct communication
with the mobile device 1240a by broadcasting in a Soft AP mode. The
direct communication is short range, communicating with the mobile
device 1240a only if it is onsite and within range of the
broadcasted Soft AP signal. The range is limited by the range of
the Wi-Fi communications circuit or module 1215, such as the range
of a standard Wi-Fi connection (e.g., 0-200 feet and in a preferred
form up to 100 or 150 feet). In alternative forms, other protocols
are used, such as Bluetooth, Bluetooth Low Energy, Near Field
Communication, Radio Frequency, Infrared, or Zigbee. In order to
work during power failures, the Wi-Fi communications circuit or
module 1215 is powered by the battery backup discussed herein. In
this way, the system is capable of communicating during normal
operating conditions via a primary communication means (e.g., a
primary wireless communication circuit) and via a secondary
communication means (e.g., a secondary wireless communication
circuit) when the primary communication means is unavailable.
[0112] The pump system 1200 includes an actuator, such as button
1214, for establishing the direct wireless communication mode
(e.g., to put the system in broadcast Soft AP mode or direct
connection mode). In the form illustrated in FIGS. 34A-B, the
button 1214 is located on the pump system 1200, and specifically on
pump 1201 itself, however, in a preferred form, the button 1214
will be located outside of the sump pit 403 such that it can be
more easily accessed (e.g., such as on the communication module
1215 in FIGS. 34A-B and 37A-B, or 520 in FIGS. 5A-B; on the remote
display 2800 in FIGS. 28 and 37A; on the controller 1201 in FIGS.
37A-B, 2900 in FIGS. 29A-B, 3120 in FIG. 31, or 3201 in FIGS.
32A-B; and/or on the integrated controller and remote display 300
in FIG. 3, 441 in FIG. 4A-B, 520 in FIGS. 5A-B). Pressing the
button 1214 allows the system to broadcast in Soft AP mode so as to
create a hotspot that remote devices can pair to in order to
continue to get pump data from the system even though the primary
wireless network connection has gone down for some reason. In some
forms, pressing the button only creates a temporary pairing, such
that it needs to be paired again when the primary wireless network
connection goes down or future service visits.
[0113] While such a button or actuator is provided for configuring
the system in or putting the system into the broadcasting Soft AP
mode or direct connection mode, in a preferred embodiment the
system will be configured to automatically start in the Soft AP
mode when initially powered up so that a technician or installer
can install the pump and confirm it is operating via a downloadable
software app without the need to obtain a network password from the
home or business owner having the pump installed. This allows the
owner to keep his/her/its network password secret and, thus, does
not require the owner share the password with others and then reset
the network password later to ensure network security. Thus, the
direct connection or Soft AP mode is useful for both setup &
install of the system, and for allowing the system to continue to
communicate data about the system with a remote device while the
primary wireless communication network is down. In some examples,
the direct wireless connection is also used during maintenance and
service of the system. A technician can directly communicate with
the control unit 1201 without needing the SSID and password for the
primary wireless communication mode. This prevents the owners of
the pump 1200 from needing to give their secure SSID and password
to a technician, and in doing so reducing their security.
[0114] FIG. 35A is a flow chart illustrating an exemplary
setup/install/maintenance process for the pump system 1200. First,
in step 3502, the person installing the system, such as a
technician, downloads the mobile application to their electronic
device, such as a smartphone. In a preferred form, the application
may be used for a plurality of pump systems 1200, so a technician
will only have to download the application once and then can use it
during each installation job. Thus, if the app has already been
installed, the technician/user can proceed to the next step. The
app will preferably be available at one or more major app stores or
marketplaces, such as the app stores for iOS and Android OS
platforms (e.g., Apple App Store, Google Play Store, etc.).
[0115] Next, in step 3504, the technician installs the pump system
1200. In a preferred form, the pump system 1200 includes a display
device, such as the remote display panel 2800 illustrated in FIG.
37A, in addition to the Wi-Fi communications module 1215. Both the
display panel 2800 and Wi-Fi communications module 1215 are
installed higher than the pumps 1220 and 1230 so that they can be
more easily accessed and/or viewed by users, such as the owner or
resident of the premises the pump system 1200 is installed in. FIG.
37A illustrates the pump system 1200 with the display panel 2800
and Wi-Fi communications module 1215 at a raised position, even
above system controller 1201.
[0116] After powering on the device in step 3506, the system is
then automatically started in the broadcast soft access point (Soft
AP) mode to serve as a hotspot that the technician can connect
his/her remote device to in order to finish installation. If for
some reason the system does not start-up in Soft AP mode or if an
error has occurred during the installation process, the technician
can put the system into the Soft AP mode by pressing the button
1214 on the Wi-Fi communications module 1215 or by selecting the
"installer portal" link on the app as illustrated in the app screen
display of FIG. 36A and then following the necessary steps to place
the Wi-Fi communications module 1215 in to its direct communication
or Soft AP broadcast mode (note: these steps are discussed further
below). Alternatively, the technician can actuate the "Reset"
button 1217 on the Wi-Fi communication circuit or module 1215 as
shown in FIG. 37B to return the Wi-Fi communications circuit or
module 1215 to its initial factory settings and try restarting
same. FIG. 37B is an expanded view of the Wi-Fi communications
circuit or module 1215 showing the direct communication/Soft AP
button 1214, the reset button 1217, and one or more status lights
1218. In a preferred form, depressing the direct communication/Soft
AP button (referred to as the LOCAL LINK.TM. button in FIG. 37B)
for a period of five seconds (5 s) causes the Wi-Fi communications
module 1215 to broadcast under Soft AP mode and act as a hot spot,
such that other Wi-Fi devices, such as the technician's smartphone
or tablet, can form a direct wireless connection therewith. In a
preferred form, however, other conditions will also need to be met
within the device firmware in order for the system to convert to
the direct communication/Soft AP mode (e.g., the Wi-Fi connection
must already be down before the system will change to direct
communications mode).
[0117] As mentioned above, in some forms of the invention the
technician can select the "Installer Portal" link illustrated in
the screen display of FIG. 36A and in step 3508 to place the system
in broadcasting mode and then select "OK" in the pop-up box of the
screen display illustrated in FIG. 36B once the pump hotspot has
been selected from the list of available Wi-Fi networks on the
device the technician is using (step 3510). However, in a preferred
form, the system is setup such that the direct communication/Soft
AP button 1214 must be pressed to get the Wi-Fi communication
circuit or module 1215 into direct communication/Soft AP mode, and
in some forms the button must be depressed for a plurality of
seconds to ensure it was an intentional activation (e.g., 5 s). In
a preferred form, the pump hotspot is illustrated with the name
WW-GEM100000XX with the latter digits being the Wi-Fi communication
circuit or module serial number (however other numbering schemes
could be used, such as the pump serial number, etc.). In the
exemplary screen display of FIG. 36C, the pump hotspot is
illustrated as WW-GEM-10000009 which relates to the Wi-Fi
communication circuit or module serial number. Once the installer
selects the pump hotspot from his/her available Wi-Fi networks, the
app should illustrate a scrollable screen like that illustrated in
FIGS. 36D-F which displays information about the current pump
system state. This allows the installer or technician to check the
status of the pump system as illustrated in step 3512 of FIG. 35A
and if successful (step 3514), the technician portion of the
installation is complete and the technician can instruct the owner
how to finish setup/registration as indicated in step 3518. If any
of the tiles of the app indicate something is wrong with one of the
system components such as the battery is dead, one of the pumps is
offline, etc., the technician can continue troubleshooting these
items until all items are fixed before departing. If the screen
display is not displayed successfully as checked in step 3514
(e.g., the app does not load, etc.), the technician can reset the
system by actuating actuator 1217 (see FIG. 37B) to reset the
system as called for in step 3516 and restart the Soft AP process
as indicated in step 3508. By going through the direct connection
and the installer portal, the technician does not need to acquire
the account and password information or the password for the
owner's Wi-Fi network.
[0118] As indicated in FIGS. 36D-F, the dashboard illustrated as
the scrollable screen display of FIGS. 36D-F is comprised of a
compilation of "tiles" or boxes that each relate to a different
system component or function and provide a status or attribute
relating to same. Thus, as illustrated in FIG. 36D, the top left
tile is entitled "AC Power" and in green the app identifies that AC
power is "ON" within the tile. Similarly, under the second tile
entitled "Battery Health" the system indicates battery health is
"GOOD". The third tile entitled "Hours of Protection" provides a
battery symbol colored in green to indicate how well the battery is
charged and estimates how long it will last for if called into
action. In a preferred form, the battery symbol and text will
indicate a combination of the data from the remote display unit
2800 illustrated in FIG. 28 which indicates if four possible states
(e.g., battery health is: good, ok, poor or needs to be replaced;
and hours of protection is: greater than 4 hours, 2-4 hours, 1-2
hours or greater than 1 only). The battery image will show varying
states of fill and can change from green to other colors reflective
of the charge (e.g., green for good charge, yellow for ok charge,
and red for poor and replace. In other forms, the battery may
remain green, but show varying stages of filled in green area to
indicate battery charge (e.g., all green for fully charged, three
quarters green for ok charge, two quarters green for poor and one
quarter green for needs replace or recharge). The lightning bolt
image or symbol shown in the battery of FIG. 36D indicates that the
battery is charger. In a preferred form, the system will use a 75
amp-hour absorbed glass mat (AGM) battery, but can also use deep
cycle batteries if preferred (e.g., deep cycle marine battery,
etc.). The battery case that the battery is kept in can be designed
for varying sizes of battery, but preferably will fit up to a
31-frame size battery.
[0119] In a preferred form, the scrollable screen display of FIGS.
36D-F will also have additional tiles indicating if the AC primary
pump is ready, if the DC pump is ready and what the current water
level is in the sump. In the form shown, the app is also configured
to provide buttons for requesting to "RUN SYSTEM TEST" and/or "MUTE
ALARM". If a run system test is selected, the system will run the
primary pump for a predetermined period of time (e.g., seven
seconds (7 s)), and then, after a short pause, run the back-up for
a predetermined period of time (e.g., seven seconds (7 s)). In some
forms, the run system test may also be configured such that the
system will check the battery to determine its state of health
(SOH), however, a preferred form of the system will run this SOH
test on a monthly basis unless initiated manually. An accurate
assessment of the battery SOH requires several days for the battery
voltage to stabilize. As the battery ages, the SOH will slowly
decline and eventually a "replace battery" indicator will
illuminate indicating the battery's ability to hold a charge is
severely compromised. If the mute alarm actuator is actuated, the
audible alarm will be muted for a predetermined period of time. In
a preferred form, the owner can press the mute button once to mute
the alarm for one hour, twice to mute the system for two hours,
three times to mute the system for three hours and so on up to
eight button pushes/eight hours. The system test and mute can be
accomplished by selecting these buttons either on the app (see FIG.
36F) or on the remote display (see FIG. 28).
[0120] In the form illustrated, the system will remain in Soft AP
mode until changed over to its primary wireless communication mode,
however, in alternate forms the system may be configured to time
out of Soft AP mode if an available wireless network connection is
detected or even without if desired. In one form, the Wi-Fi
communication module 1215 includes a timer and stops acting like a
hot spot after a predetermined amount of time. In some forms, the
predetermined amount of time is an amount of time in hot spot mode
with no external electronic device connected. Once the hot spot
mode is terminated, the Wi-Fi communication module 1215 attempts to
re-establish connection to any stored networks, such as to the
local wireless router.
[0121] FIG. 35B illustrates an exemplary flow chart process 3550 by
which the homeowner or resident finishes installation of the pump
system and/or uses the pump system 1200 after installation. As in
the process 3500, first the homeowner installs the software
application on a desired electronic device in step 3552. It should
be understood, however, that a technician, homeowner or other user
of the system could setup the system and use same by accessing a
website portal as well in case they do not have a smart phone or
wish to use an App version of the system. For simplicity sake, this
disclosure assumes the App will be used and, thus, describes setup
and use of the system using the App example. When the application
is opened a sign-in screen is displayed, see FIG. 36G. If the
homeowner already has an account and password, it can be entered on
this screen using the input device of the owner's electronic
device, such as the touch screen on a smartphone or tablet. If not,
the user selects sign-up on the screen of FIG. 36G to access the
sign-up page of FIG. 36H and create an account and register the
pump system. Once an account is created, the user will only be
required to visit the sign-in page of FIG. 36G and no longer will
need to visit the sign-up page of FIG. 36H unless desired.
[0122] At the sign-up/registration page of FIG. 36H, the homeowner
registers an account in step 3554 by entering information into the
displayed form, see FIG. 36H. After registering an account, the
user establish a wireless communication for the pump by selecting
the preferred wireless network and entering any necessary password
for same in step 3556. After a wireless network is established, the
owner will see the scrollable app screen display of FIGS. 36I-K
which provides information similar to that discussed above with
respect to screen display FIGS. 36D-F to check provided status of
pump systems in step 3558. If not already apparent, FIGS. 36I-K are
meant to collectively display all the content on the scrollable
screen display and thus illustrate overlapping repetitive portions
of the screen display (this is true for FIGS. 36D-F as well). In
some forms, the homeowner's initial setup will use the direct
connection technique mentioned above until the wireless password or
other required information is entered. Once entered, however, the
system will communicate via the primary wireless connection and
only use the direct connection communication (or the secondary
wireless communication method) if the primary wireless
communication method is not available.
[0123] If the primary wireless communication connection is lost (as
is checked in step 3560), the application displays the fault
screen, see FIG. 36M. The fault screen notifies the user that the
pump system 1200 is offline, and provides a link to establish a
secondary wireless communication method, e.g., the direct
connection or Soft AP connection discussed above (see the link
entitled LOCAL LINK.TM. in offline banner on upper right of screen
display in FIG. 36L). When this occurs, the status boxes on the
screen or tiles are faded or greyed out to convey to the viewer
that they are not being updated and reflect the last known data for
each field/tile prior to the primary communication network becoming
unavailable.
[0124] As with the technician installation discussion above, the
pump owner will be prompted to establish a direct connection via
the secondary wireless communication method (e.g., the direct
connection or Soft AP mode) beginning with the pop-up window of
FIG. 36M in step 3562. Once selected, the user is prompted in step
3564 to hold the direct connection button 1214 (see FIG. 37B) in
for five seconds (5 s) (or actuate it for 5 s) to place the pump
communication module in the Soft AP broadcasting mode to establish
a direct connection with the owner's electronic device. Once done,
the owner must select the pump system hotspot from the list of
available wireless networks displayed on the user's electronic
device as illustrated in FIG. 36O and indicated in step 3566 and
then select "OK" in FIG. 36N. Again, in the form illustrated, the
pump system hotspot is identified as WW-GEM-10000009. Once
selected, the owner will see pump system status data similar to
what is shown in FIGS. 36D-F and as specified in step 3568. If the
primary wireless network is not available due to a power outage
(meaning loss of line power or mains power), the initial screen may
be modified to list the AC Pump tile as "OFF" and list the AC
Primary Pump tile as "OFFLINE" due to no line power being available
as illustrated in screen display or shot FIG. 36Q. In the exemplary
embodiment of FIG. 36Q, the battery health and hours of protection
tiles have also been altered to show what the app may display (at
any time) if the battery health is poor or if the battery has only
one hour or slightly more of battery life left just to give an
exemplary illustration of same. In a preferred form, these battery
life and hours of protection tiles will be the same as those shown
in FIG. 36I meaning that the battery is fully charged and in good
health even if the AC pump is OFF/OFFLINE.
[0125] If the primary wireless communication network becomes
available again while the direct connection is established (as is
checked in step 3570 of FIG. 35B), the system prompts the user by
asking if he/she wishes to terminate the direct connection and go
back to the primary wireless connection as illustrated in step 3572
and FIG. 36P. If the user selects leave the direct connection
(called LOCAL LINK.TM. in FIG. 36P), the system will drop the
direct connection and reconnect to the primary wireless network
connection and begin checking the status of the pump system as done
in step 3558 of FIG. 35B. If the user elects to stay connected
under the secondary communication connection (i.e., the direct
connection), the system will continue to check the status of the
pump system as done in step 3568. In the form illustrated, the
system refreshes its status data much quicker under the primary
communication connection than it does under the secondary
communication connection (e.g., primary communication connection
refreshes almost instantaneously (microseconds or milliseconds)
versus the secondary communication connections much slower refresh
rate of three or more seconds). In addition, in some systems, the
user may not be able to utilize his/her electronic device for other
uses while it is under the secondary communication connection
(e.g., the user will not be able to utilize other available
wireless networks such as other Wi-Fi networks, 4G or LTE or may
have limited usage of other networks or features on the user's
electronic device such as limits on broadband cellular networks and
data or apps that would otherwise be usable on the user's device).
Thus, it is contemplated that most users will opt out of the
secondary communication connection/direct connection in favor of
the primary communication connection. As mentioned above, the
system may also be configured to connect the user out of the direct
connection or secondary communication connection after a
predetermined period of time has been detected. In yet other
embodiments, the system may be configured to do this automatically
without prompting the user in the manner shown in FIG. 36P and step
3572 if desired.
[0126] The system 1200 can include a control unit 1201, which can
be provided as a part of the system 1200, or as an independent, or
replaceable component. The control unit 1201 can include a backup
battery 1234, and two control modules 1210 and 1211. Alternatively,
the two control modules 1210 and 1211 can be independent components
that are installable separately with respect to respective pump
systems 1220 and 1230. Each pump system 1220 and 1230 can include
an AC pump or a DC pump, each of which can be associated with a
sensor such as an air tube/pressure sensor 1224 or a float switch
1235. Each control module 1210 and 1211 can be used to operate the
corresponding pumping system, while in turn communicating via
network 1250 with the other module. The remote display unit 1240
can display the results of the communications between the two
systems. For instance, the remote display unit 1240 may communicate
via Bluetooth, 4 wire, other radio frequency transmission or
another similar technique with the control unit 1201. In this
manner, the two systems can be configured to operate in tandem,
though the systems may have originally been provided or purchased
independently. For example, with this configuration, the primary or
secondary pump may be able to take over the operational tasks of
the other pump and, in a preferred form, even operate the other
pump such as when a controller on one pump goes bad or fails.
Ideally, in such a failed controller situation, the controller that
assumes operational control of the system will be able to operate
both pumps so that the pumps may be cycled on alternately (or
alternately activated) to prevent one pump from dying before the
other due to excessive use as compared to the other. Another
benefit of having the controllers set up in this manner is to allow
the controller that has assumed operational control to activate
both pumps simultaneously or at least together at some point should
fluid be rising at a rate that requires both pumps to operate in
order to keep up with the rate the fluid is rising.
[0127] Thus, in summary a pump system is provided which
communicates via a primary pump communication circuit or network
during regular operation and via a secondary pump communication
circuit or network when the primary pump communication circuit or
network is unavailable. In some forms, the primary communication
circuit or network is a wireless network and the secondary pump
communication circuit or network is a direct communication network.
For example, in a preferred form, the primary communication circuit
or network is a Wi-Fi local area network and the secondary pump
communication circuit or network is a direct communication network
using Soft AP, Bluetooth, Bluetooth Low Energy, Near Field
Communication, Infrared or Zigbee communication protocols.
[0128] A battery back-up pump system is also contemplated herein
utilizing the above mentioned pump system. In one form, the battery
back-up pump system includes an AC pump, a DC pump, a controller
having a primary wireless communication circuit and a secondary
wireless communication circuit. The primary wireless communication
circuit preferably communicates via a Wi-Fi local area network and
the secondary wireless communication circuit communicates via a
direct connection with a paired remote electronic device when the
Wi-Fi local area network is unavailable.
[0129] A benefit to having redundant systems as discussed in the
embodiments above, is the ability to prevent flooding due to a
system or component failure and to give a pump owner peace of mind
as to the operation of his/her pump even when network and/or power
outages occur. However, as mentioned herein, another benefit to
such redundancy is the ability to service one pump while allowing
the other pump to continue to operate. Furthermore, as mentioned
above, an advantage to having a redundant controller configuration
is the ability to continue to offer pumping capabilities when
failures occur. As also mentioned, it is desirable to configure the
system so that a failed component (e.g., pump, controller, etc.)
can be removed while the other component or remaining components
continue to operate or offer pumping capabilities. As such, in a
preferred form, the controllers may be configured so that separate
circuits or circuit modules are utilized to allow a controller to
be removed and serviced or replaced while the other controller
remains in place and operational. Similarly, it is desirable to
have all other modules of the system to offer redundancy and
serviceability without disrupting at least partial operation of the
system. Some preferred systems in accordance with this disclosure
will also notify a user of any system or component failure or
malfunction so that the systems or components may be serviced
timely.
[0130] The present disclosure presents examples of a sump pump
system that includes a primary sump pump, which can have an AC
power supply, a backup sump pump having a DC power supply, and a
controller. The controller can be in electrical communication with
the primary sump pump and the backup sump pump, the controller
configured to communicate wirelessly with at least one remote
device.
[0131] In some examples, the controller can be configured to
control other systems as a central control module (e.g., sewage or
utility pumps or drainage pumps located elsewhere such as outside
of home/building).
[0132] In some examples, the controller can be configured to
communicate with other equipment in a home, such as HVAC equipment,
telephone or communication equipment, refrigerators, freezers, ice
makers washers, dryers, dishwashers, or other appliances, water
meters, home security systems, or the like.
[0133] The controller can supply output signals to support multiple
notification technologies (analog, cellular, digital, other). The
system could be configured to send one-way "push" notifications
only or, alternatively, provide two-way communication (e.g., remote
actuation of pump, diagnostic check, etc.).
[0134] The control components of the system, such as system 300 of
FIG. 3, can be configured in a variety of ways. For example, they
can be combined with the battery charging electronics and mounted
in a highly visible location in the surrounding area of the unit
(e.g., on the basement wall for a sump pit, or on the discharge
pipe near the sump pit, etc.). In some examples, the system 300 can
also include a 12 V DC output 370 and/or an AC output 380. These
outputs 370, 380 can be used to provide power to other ancillary
devices or equipment, such as communication devices, signaling
equipment, sensors, test equipment, light sources, etc.
[0135] The sump control system enclosure can also accommodate the
battery charging electronics, thereby moving the charging
components away from the harsh environment of the battery box and
into an area more convenient for viewing & operation by the
home owner (ref. sealed sump units with Radon sensors).
[0136] In some examples, the system includes a pressure switch
that, along with the controller, can also operate both the first
and second (e.g., AC and DC) pumps, thereby alleviating the use of
multiple float-type switches in the sump pit so that the system is
more compact and fits into smaller diameter pits found in many
older homes.
[0137] In the event of high water intake, the central controller
can operate both AC & DC (or two A/C) pumps simultaneously to
remove a higher volume of water from the basement. The central
controller could also alternate activation between pumps to
effectively "exercise" each system to ensure operation and to
balance the number of cycles on each unit.
[0138] The central control system can supply output signals to
support multiple notification technologies (analog, cellular,
digital, other). The system could be configured to send one-way
"push" notifications only or, alternatively, provide two-way
communication (e.g., remote actuation of pump, diagnostic check,
etc.).
[0139] The controller can include a communication module and is
thus configured to communicate wirelessly via a network. For
example, the controller can be configured to communicate via a
Wi-Fi signal or via a cellular network. In some examples, the
controller can also monitor various events relating to the
operation of the sump pump system. For example, the controller can
be configured to monitor the operating status of the AC power
supply, the power level of the DC power supply, the operating state
of the primary and/or backup sump pump, problems during operation
of the pump, a cycle count of the primary and/or backup pump; an
electric current draw rate of the sump pump system, a water level
at or around the sump pump, and the rate at which the water level
is rising or falling in the sump.
[0140] The controller may be configured to perform diagnostic
operations on at least one of the primary sump pump and the backup
sump pump. The controller can also be configured in some examples
to monitor and communicate in real-time information relating to the
fluid level, the battery state, the current usage, and the on/off
status of the equipment of the sump pump system. In some
approaches, the controller includes a communication module, is
configured to communicate notifications to a remote device, such as
a smart phone, a tablet computer, or anther computing device. The
communications module could be a separate unit or integrated into
the control enclosures. The controller can be configured to
communicate notifications at predetermined time intervals, or
during predetermined time periods.
[0141] The controller can be configured to automatically
communicate notifications in response to the detection of certain
events. For example, the controller may be configured to
communicate notifications relaying information pertaining to a
power outage, a change in the operation state of the primary and/or
backup sump pump (e.g., the backup pump turns on, off, or
increases/decreases in pumping rate, frequency of operation,
cycles, etc.), the detection of a battery level of the DC power
supply below a predetermined threshold (e.g., the battery has less
than 50%, 25%, 15%, 10%, or 5% power, etc.), a detected problem in
the operation of the pump, a detected cycle count of the primary
and/or backup pump exceeding a predetermined threshold (e.g., the
pump has performed about 50% of the life expectancy of the pump),
an electric current draw rate of the primary and/or or backup sump
pump above a predetermined threshold, a detected water level rising
above and/or falling below a predetermined threshold, and a
detected water level rising and/or falling at a rate above and/or
below a predetermined threshold (e.g., water is rising faster than
the pumping system can pump). In some aspects, the controller is
also configured to monitor and report on the brush life of the DC
pump motor (or any pump motor) by determining the total "on" time
(i.e., the total time in which the pump has been running)
throughout the life of the pump. Thus, once the motor has been
operated or cycled on for a predetermined amount of time associated
with a certain percentage of motor brush wear, the system will
provide a notice (e.g., audible and/or visual alarm, data
notification such as text or alert, audible communication, etc.).
This predetermined amount of wear can be any amount desired, (such
as 75% wear, 80% wear, 90% wear, 95% wear, 100% wear, etc.), and
may include multiple notices to increase the likelihood that the
motor will be timely serviced before a failure occurs (e.g., such
as by replacing the motor brushes before they reach or by the time
they reach what is predicted to be 100% wear).
[0142] Some versions of the controller are configured to
communicate notifications that offer coupons for new system in
response to the controller detecting a life cycle count has
exceeded a predetermined threshold. For example, when the
controller detects that the pump has reached the midway point of
the life expectancy of the pump (or its life expectancy), the
controller may send coupons, reminders, or other notifications to
alert a consumer to purchase a new pump and/or perform service or
maintenance on the pump. In some aspects, the controller may
communicate notifications that offer an extended warranty option
for systems that the controller has detected a life cycle count
that exceeds a predetermined threshold (e.g., indicating that the
user may want to pay for such extended coverage given its system is
detected to be working at usage levels that exceed normal usage
guidelines or thresholds). In some approaches, the controller is
configured to track unit parameters that provide insight into
whether a warranty should be honored. For example, the controller
can track whether warning notifications have been properly
addressed and/or ignored by the pump owner. That is, the controller
may determine that a sump pump system failure is a result of
ignored notifications communicated by the controller, and use this
information to determine if warranty status is still
authorized.
[0143] In some forms, the controller can receive communication
signals from a remote device, and perform functionality in response
to the communication signals received from the remote device. For
example, the controller can be configured to receive signals from a
user operating an application on a remote device (e.g., a smart
phone) that instruct the pump to turn on, turn off, activate a
backup pump, etc. In response the controller will effect operations
of the pump accordingly (e.g., self-test, self-diagnostics checks,
etc.).
[0144] Some examples described herein also present a mobile
application used in connection with a sump pump system. The
application can be configured to operate on a remote device, such
as a smart phone, a tablet computer, or the like ("app"). The
mobile "app" may include an interface that can provide information
to the user, and can allow the user to execute various
functionality.
[0145] In some approaches, the app is configured to operate one or
more of a variety of features. For example, the application can be
configured to operate one or more of the following
features/functions: [0146] (1) display key system status parameters
(water level, battery state, power on/off); [0147] (2) perform
diagnostic check/systems test; [0148] (3) provide real-time fluid
level feedback, battery state, current usage, on/off state, etc.;
(the app can provide active feedback or a closed-loop controller
concept); [0149] (4) track real-time or time lapsed pump usage and
prompts notifications at desired time periods; [0150] (5) offer
coupon for new system once predetermined life cycle count has been
reached; [0151] (6) offers extended warranty option when pump is
approaching original warranty limit; and/or [0152] (7) tracks unit
parameters to provide insight on whether warranty should be honored
or not (e.g., if system repeatedly advised user of problems and
failure was due to user ignoring notifications). It should be
understood that reference to "real-time" as used herein may mean
exactly that, i.e., real-time data, or it may include slightly
time-delayed data that may be better described as nearly real-time
or not old/historical data.
[0153] The system can be configured to execute/display/operate the
same functions on a display associated with the unit itself (e.g.,
a display interface at or around the controller or integrated
module) that are executed on the app. Some examples described
herein also apply the use of a pneumatic pressure switch that
eliminates and/or reduces the number of moving parts, which can
result in an increase in system reliability. FIGS. 4A-B are
sketches showing an example system 401 that uses a pneumatic
pressure switch. The system 401 includes a sump pump 400 and a
pressure tube 440 in a sump pit 403. The sump pump 400 is connected
to a power source 410 (e.g., a 120 V AV 60 Hz outlet) via a sump
pump power cord 404, and is configured to pump fluid out of the
sump pit 403 through the pump discharge outlet 460. The pressure
tube 440 has a pressure tube inlet 447, and is connected to a
switch device 441 via a flexible tubing 442. The switch device 441
can be or can include a pressure transducer, a printed circuit
board, a microprocessor, a triac switch, or the like. A piggyback
cord 445 supplies electrical power to the switch 441 from the power
source 410. The pneumatic pressure switch system 401 of FIGS. 4A
and B can be configured to flush air after a predetermined period
to recalibrate and eliminate problems with condensation build-up or
tube leakage. In some examples, the pneumatic switch tube 440 could
be of a basic plastic construction, or wholly or partially
constructed from copper to help reduce the build-up of iron ochre.
While it is known to use capacitive sensors in sump pump systems
(see, e.g., U.S. Pat. No. 8,380,355, and U.S. application Ser. No.
13/768,899 (Mayleben et. al.), owned by Wayne/Scott Fetzer Company,
both of which are hereby incorporated by reference in its
entirety), such systems may evoke additional steps to ensure that
the air tube is back to atmospheric pressure. The present
disclosure describes systems that employ sensors that are adapted
to operate so that the water level is held below an opening. In
this manner the fluid level in the pit maintains a certain level
with respect to the fluid level in the tube (e.g., the pit and tube
fluid levels do not have to be equal or level with one another, but
rather simply correlate with one another so that the level in the
tube can be used to calculate a corresponding level of fluid within
the pit). Further, in some examples, the systems will be configured
to turn on after a predetermined time so that the air in the tube
returns to atmospheric pressure.
[0154] Some examples described herein provide a variety of uses and
functionality. One embodiment includes a pump volute design that
supports close nesting of pumps. Another embodiment includes a
water level sensing algorithm that receives inputs from an air tube
to a PCB mounted pressure transducer. Though the air tube can be
arranged in a variety of configurations, in some aspects the air
tube may be arranged in a generally vertical orientation. Another
embodiment includes the ability to remotely mount the
sensing/switching electronics out of the sump pit. Some examples
described herein provide an integrated water level sensing & DC
battery charger electronics in one enclosure. Some aspects
described herein provide a communications module that can receive
& send data from the central control unit. Some examples
include a mobile application that can receive push notifications
showing system status. Still other examples, offer two-way data
communications between App & central control to allow remote
system test.
[0155] Some examples described herein present a redundant control
system for a pumping system or pumping arrangement. The pumping
arrangement has at least one pump, and can include a primary (e.g.,
an AC) pump and a secondary or backup pump (e.g., an AC backup pump
or a DC pump). The redundant control system includes a primary
controller that directs or manages operation of the at least one
pump, and a secondary controller that controls operation of the at
least one pump in the event that the primary controller is
inoperable, unavailable, or otherwise non-functional. In some forms
the primary controller controls operation of the primary pump and
the secondary controller controls operation of the secondary or
backup pump. In some examples, the secondary controller is
configured to control operation of the first pump in the event that
the primary controller is inoperable.
[0156] The controllers can be either AC powered, DC powered, or
both. For example, the primary controller may be an AC powered
controller and the secondary controller can be a DC powered
controller, but also be provided with an AC supply that keeps the
DC powered controller charged. The controllers can take on a
variety of forms. For example, in one aspect, the primary
controller may include or be a primary microprocessor. The
secondary controller can also be a software executing apparatus,
such as another microprocessor, a logic circuit, or the like. In
certain embodiments the secondary controller can perform all of the
functionality of the primary microprocessor. However, in other
embodiments, the secondary controller is limited in functionality,
and can only perform some of the duties of the primary controller.
For example, the secondary controller may only be able to turn on
and off the pumps of the pumping arrangement. In some aspects, the
secondary controller is software-free utilizing a relay or a
mechanical switch. In some aspects, the secondary controller
includes a monitor configured to observe operation of the primary
controller, and can assume operation of both the primary and
secondary pumps, if required.
[0157] It should be understood that the presently described pumps,
systems, controllers, and related equipment can be utilized in a
variety of different methods or processes. That is, the present
disclosure contemplates using the described pumps, systems,
equipment, or the like in a variety of methods, processes, or
techniques that utilize the advantages of the related equipment.
For example, one method involves reducing the footprint (e.g.,
reducing the overall occupied space) of a two-pump pumping system.
The method includes connecting a primary pump check valve and a
secondary pump check valve to discharge outlet with a cross-over
pipe that extends over the primary pump and the secondary pump,
placing the two-pump pumping system into a sump pit, and connecting
the discharge outlet to create a redundant system.
[0158] Another method involves activating a pump of a sump pump
system. The method includes providing a primary controller
electrically connected to a primary pump, whereby the primary
controller has a primary interface for communicating with a primary
and secondary pump. The primary interface is operated to activate
the primary pump, a secondary pump, or both pumps, when the fluid
level sensor indicates a predetermined fluid level has been
reached.
[0159] Another method involves placing a two-pump pumping system
into a sump pit. The two-pump pumping system includes a first pump
having a first volute and a first discharge pipe segment, and also
includes a second pump having a second volute and a second
discharge pipe segment. The first and second discharge pipes are
connected to one another to interconnect the first and second pumps
to one another. The two-pump pumping system can then be placed into
a sump pit as an integrated assembly. In such configurations, a
check valve would be positioned in line with each pump discharge or
in other forms an isolation valve like the one discussed further
below could be used.
[0160] Yet another method involves pumping fluid from a sump pit
with a two-pump pumping system. The method includes pumping fluid
from the sump pit with the primary sump pump, and detecting one or
more conditions associated with at the pumps and/or the sump pit
(e.g., the fluid level in the sump pit). In response to detecting
one or more predetermined conditions, the secondary pump is then
activated to pump fluid from the sump pump. For example, when the
method detects that water in the sump pit has exceeded a
predetermined height, the secondary pump can activate to facilitate
the pumping of the primary pump.
[0161] Other methods relate to the transmission of notifications
that relate to a pumping system installed in a sump pit. First, one
or more pumping conditions associated with at least the pumps or
the sump pit are detected via one or more sensors. In response to
detecting one or more conditions (which may be predetermined), a
controller will transmit a signal, for example, to a remote device.
The signal can include information or otherwise notify a user of
the circumstances associated with the detected conditions.
[0162] As discussed above, some examples of the dual pumping system
include dual pumps that are integrated via a shared volute or other
structural designs that combine the volutes of two pumps into a
common space. These pump volutes can be manufactured together as a
single component, or they can be joined via components that inhibit
separation of the two pumps. For example, the pumps may be cuffed
or otherwise connected via a bracket or other structure.
[0163] FIG. 16A shows an exemplary sump pump assembly 1600 with a
bracket 1610 that cuffs the two pumps together in accordance with
examples described herein. The bracket 1610 is shown removed from
the pump assembly in FIG. 16B for clarity. In this example, the
volutes for each pump have an outlet portion, which may comprise a
collar 1630 and 1631 configured to attach to a discharge pipe 1660.
The bracket 1610, may comprise annular portions 1612 and 1614
configured to surround the collars 1630 and 1631, respectively,
thereby embracing or "handcuffing" the two pumps together. The
brace can take on a variety of forms and configurations, but in
some forms, the brace will extend between the two pumps, and will
connect to each pump on opposing sides of the assembly 1600. In
FIGS. 16A and B, the bracket 1610 is shown to have a bridge
configuration with a raised portion 1635 between the two annular
ends 1612 and 1614. This raised bridge portion 1635 raises up so as
to support a pneumatic pressure tube 1620 box or housing, which can
attach to a tube 1621 via a connector 1622, and function as a
sensor to control operations of the pump assembly 1600.
[0164] In other configurations, however, the bracket can have a
straight, flat, or planar configuration, as shown in FIG. 17. In
this example, the bracket 1710 has a dumbbell like shape, with two
end portions 1712 and 1714 separated by a central portion 1730 that
is planar with the ends 1712 and 1714. Such a configuration may
provide added strength and stability to the assembly, reducing the
number of points of weakness that may be present on a bridge shaped
bracket, particularly in situations where the bridge is not used to
support a pressure tube.
[0165] As discussed above, some pumping systems described herein
include a pressure tube that can serve as a sensor to control the
pumping of fluid by the system. The pressure tube can be installed
or installable with respect to the system in a variety of different
configurations. In FIGS. 16A and B, the pressure tube 1620 is held
in between the two pumps, and supported by a bridge shaped bracket
1610. In other configurations, however, the pressure tube can be
stored within a housing, such as the housing 1820 shown in FIG. 18.
The housing 1820 can be configured to attach to the pump assembly
along an outer periphery of the assembly. For example, the housing
1820 may include attachment mechanisms 1825 (such as holes or
protrusions) that facilitate attachment to an upper surface of a
volute of a pump assembly. In some forms, the housing 1820 may have
a curved shape and be configured to correspond with the contour of
the pump assembly to provide a more streamlined appearance. The
housing 1820 may include an aperture 1822 that may be configured to
hold and support a pressure tube.
[0166] The present application also describes examples of sump pump
assemblies that utilize various check valve systems that control
the flow of fluid out of the pump, and inhibit the flow of fluid
back into the pumps. Many systems that utilize multiple pumps are
configured to discharge both pumps through a common discharge pipe.
This avoids the additional cost of routing a second line dedicated
to the secondary or backup pumping unit. However, when this
technique is employed, in particular with centrifugal pumps, it may
be important to utilize check valves in the discharge lines of one
or more of the pumps (and preferably both) to block or inhibit flow
from one pump back into an inactive pump unless an isolation valve
like the one discussed below is used.
[0167] FIGS. 19A and 19B demonstrate why check valves are preferred
in dual pump systems with a shared discharge pipe. In FIG. 19A, the
dual pump system 1900, which utilizes check valves, includes an
active pump 1910 and an inactive pump 1912 that both pump through
outlets toward a common discharge pipe 1960. In this system 1900,
the flow path from each pump toward the discharge pipe 1960
includes a check valve 1961 and 1962. These check valves allow
fluid from the pump to pass out of the pump, but inhibits fluid
from passing backward into the pump. Thus, in FIG. 19A, fluid
pumping out of the pump is directed out of the discharge pipe, and
check valve 1962 stops fluid from recirculating into the inactive
pipe.
[0168] FIG. 19B shows a dual sump pump system 1901 that does not
utilize check valves. In this system, fluid from the active pump
1910 is pumped toward the discharge pipe 1960. But because the
secondary or backup pump 1912 does not utilize a check valve, some
or even all of the fluid pumped by the active pipe is recirculated
back through the backup pump and back into the sump pit. Not only
is this system ineffective and inefficient as the system
essentially is recirculating fluid back into its own system, which
can result in flooding the surrounding environment and/or be
harmful to the inactive pump.
[0169] Certain aspects described herein utilize a system that
employs dual check valves in the outward flow path of each pump.
FIG. 20 shows an example of a sump pump assembly 200 utilizing
separate check valves 2024 and 2025, for in the outward flow path
for each pump. This situation is similar to the one described in
FIG. 19A. This dual check valve configuration is highly preferred
for operation in pumping systems with a common discharge. However,
in certain situations it may be desirable to reduce the number of
check valves provided in a system without effecting the end result,
such as by using an isolation valve. Accordingly, some aspects of
this application relate to an isolation valve (also referred to as
a diverter valve) that can conserve space and cost by providing a
single valve that operates to the same effect of a dual check valve
system. That is, the isolation valve can effectively allow each
pump to pump fluid toward a common discharge pipe when they are
active, while also inhibiting or preventing the recirculation of
fluid back into an inactive pump. Such a system may be utilized to
allow both pumps to pump fluid simultaneously, thereby allowing the
system to operate in a maximum pumping mode when water levels rise
to a particular level.
[0170] FIGS. 21-24 show various examples of isolation valves or
single piece discharge units that can be used in place of a dual
check valve system. FIG. 21 shows an example of a dual sump pump
system 21 with an isolation valve 2110 that controls the flow from
each of two pumps 2120 and 2130 toward a common discharge pipe
2160. This isolation valve 2110 can be used to stop or inhibit the
backflow of fluid through an inactive pump, while simplifying the
pump system and reducing the overall number of components and
connections required. As shown, the isolation valve 2100 can also
serve as a fork or junction that combines the two outward flow
paths from each pump into a single flow path, which in turn flows
into the common discharge pipe 2160. The embodiments with a single
flap or flapper are diverters only and, in preferred forms, will
still utilize a downstream check valve to ensure fluid does not
recirculate. Conversely, the embodiments with two or dual
flaps/flappers will preferably be sufficient to prevent
recirculation of fluid so that downstream check valves are not
needed.
[0171] FIGS. 22A and 22B show a cross section of an isolation valve
220 in various states of operation. The isolation valve 2200 has an
inverted U or Y shape, representing a fork or junction where two
flow paths 2210 and 2220 from two separate pumps join together.
Each flow path 2210 and 2220 flows through a junction toward an
outer flow path 2300 in the valve 2200, which in turn connects to a
common discharge pipe 2260. Within the junction, the valve 2200
includes a flapper 2250 that rotates about a hinge 2252 among a
variety of configurations.
[0172] In one configuration, shown in FIG. 22B, the flapper is
angled to the left, thereby blocking or obstructing the flow path
2210. In this configuration, the flow path 2220 is clear to pump
fluid toward the discharge outlet 2230 while the other flow path
2210 is obstructed so that recirculated or pumped fluid will not
flow back toward the pump. In another configuration, the flap 2250
may move to the right, thereby allowing flow from the flow path
2210 while preventing recirculated flow back down path 2220. In
still other configurations, the flapper 2250 may be positioned in
the center, thereby allowing outward flow from each flow path 2210
and 2260.
[0173] The flapper 2250 of FIG. 22A is shown as a 2-piece
configuration, having a first flapper part 2254 on the left side
configured to obstruct flow path 2210 and a second flapper part
2255 on the right side configured to obstruct flow path 2220. When
one flow path is open, a flow path may flip a flapper part adjacent
to the other flapper part. In preferred forms, this eliminates the
need for having any check valves downstream.
[0174] The flapper 2250 may be configured to move based solely on
the mechanical forces of the pumped fluid. For example, the force
of water or other fluid pumped by the pumping system can push the
flapper 2250 to an open position. The flapper 2250 can include a
spring hinge that defaults the flapper 2250 or both flapper parts
2254 and 2255 to a closed position when no fluid is being pumped
through the respective flow paths 2210 and 2220. In some
situations, the flapper 2250 or its components can be mechanically
or electronically controlled via a system that toggles the flap
2250 between positions. The control system may communicate with the
pumping system, or may detect that the pumping system is operating
in a certain way, and thus move the flap 2250 to an appropriate
position. This control feature may allow the system to determine an
ideal flapper 2250 location depending on the amount of fluid being
pumped from each flow path, and may allow the system to coordinate
optimum flow rates. This control may also allow the system to
execute an override to move a flapper in a situation when a
particular pump is not operating or not functioning properly.
[0175] FIG. 23 shows a cross section of one example of an isolation
valve 2200. Unlike the embodiment of FIGS. 21 and 22, which has an
inverted U or Y shaped configuration that involves a bend or curve
in the outward flow paths from each pump, the isolation valve 2300
of FIG. 23 allows one flow path 2320 to have a straight or linear
flow path. In this configuration, a first flow path 2310 coming
from a first pump angles toward the discharge portion 2330 of the
valve, thereby joining flow paths with the second linear flow path
2320. Because the first flow path 2310 has a bend, the flow
resistance may be increased as compared to the second linear flow
path 2320. As such, the diameter of this pipe may be increased to
account for the flow rate drop. Alternatively, the diameter may be
generally the same, but the first flow path 2310 may be configured
to attach to a stronger pump, for example, an AC powered pump,
which may be more equipped to handle pumping through such a flow
path. In this way, the linear flow path 2320 may offer lower flow
resistance to a weaker pump, for example, a DC or battery powered
pump, or a smaller pump that may be used as a backup or secondary
pumping source. In this way, the backup pump can be configured to
pump fluid in a "straight shot" configuration, thereby reducing the
flow resistance to a pump that may not be equipped to handle as
much flow resistance.
[0176] The valve 2300 includes a flapper 2350 that rotates between
positions that enable flow through the linear flow path 2320 while
obstructing recirculated flow through the curved flow path 2310, as
shown in FIG. 23. In another configuration, the flapper 2350 may
obstruct the flow back into the linear flow path as fluid flows out
of the curved path 2310. In still other configurations, the flapper
2350 may be positioned between the two flow paths, thereby enabling
outward flow from each path, for example, when both pumps are in
operation.
[0177] This straight shot configuration can be used in connection
with a sump pump system that has dual pumps, as described in
accordance with several of the embodiments presented herein. That
is, the straight shot configuration may be utilized in an assembly
that utilizes a primary pump to pump fluid through a primary outlet
pipe or flow path toward a common outlet pipe, and a secondary or
backup pump configured to pump fluid through a backup outlet pipe
or flow path toward the discharge outlet pipe. The terms primary
and secondary or backup here are used for identification purposes,
and may not necessarily represent functional roles of the pumps.
For example, in some embodiments both pumps may be AC powered pumps
that can interchangeably execute "primary" pumping capabilities. In
other examples, both pumps could be DC powered pumps that
interchangeably execute primary pumping capabilities, or that are
both used redundant backups as a part of a larger pumping
system.
[0178] This configuration may employ a straight shot feature so
that one of the pumps can pump fluid through an outlet pipe or flow
path that runs generally parallel with the discharge outlet pipe,
and thus does not experience a substantial pressure drop or
increase in flow resistance. This straight shot feature may employ
the use of an isolation valve or outlet flow path unit as shown in
FIGS. 23 or 26. Because this isolation valve includes one straight
flow path, a second flow path may include a bend or curve, thereby
giving rise to a pressure drop or potential flow resistance. In
some situations, the bend can be gradual or angled, as shown in
FIGS. 23 or 26, but in other examples, other configurations may be
used. For instance, the isolation valve may include a curved flow
path that intersects a discharge outlet pipe, or an outlet portion
of the isolation valve at a right angle. In certain situations, the
pumping assembly will be configured so that the straight shot
feature aligns with a pump (e.g., the secondary or backup pump)
that has a lower pumping power among the multiple pumps. In this
way, the weaker or backup pump can pump effectively regardless of
which pump is operating. In backup outlet pipe is an extension of
the discharge outlet pipe.
[0179] FIG. 24A shows another example of an isolation valve 2400.
FIGS. 24B-D show cross sections of the isolation valve of FIG. 24A
in various states of operation accordance with other examples
described herein. In this configuration, the isolation valve 2400
has two linear and parallel flow paths 2410 and 2420 that meat at a
junction 2405 to converge into a single outward flow path 2430.
Positioned in the junction 2405 is a flap 2450 that toggles between
a position that blocks flow back into path 2410 (FIG. 24C), a
position that blocks flow back into path 2420 (FIG. 24D), and a
middle position (FIG. 24B) that allows flow out of both paths 2410
and 2420. In this dual flow configuration of FIG. 24B, the
configuration of the valve 2400, the junction 2405, and the flap
2450 allows both flow paths 2410 and 2420 to pump fluid at a
relatively high flow rate, without experiencing substantial flow
resistance and thereby suffering pressure or flow rate drops at the
junction.
[0180] As noted, various forms of these isolation valves can be
used in connection with a variety of the various pumping systems or
assemblies described herein. In one example, a sump pump system
includes a tandem sump pump unit, which in turn includes a primary
pump and a secondary pump, each being arranged to pump fluid toward
the discharge outlet. The system also includes an isolation check
valve in fluid communication with each of the primary pump, the
secondary pump, and the discharge outlet. The isolation check valve
operates in multiple operating configurations, including a first
configuration where the isolation check valve permits the flow of
fluid from the primary pump to the discharge outlet but obstructs
the flow of fluid out from or back toward the secondary pump. This
configuration can involve the use of a flap that pivots to close
and seal a flow path toward the secondary pump, but leaves the flow
path from the primary pump generally unobstructed.
[0181] The isolation check valve may also operate in a second
configuration wherein the isolation check valve permits the flow of
fluid from the secondary pump to the discharge outlet but obstructs
the flow of fluid out from or back toward the primary pump. This
can be achieved, for example, by rotating the flapper unit from the
first position where the flow path form the secondary pump is
cleared, but the flow path back to the primary pump is obstructed
and sealed.
[0182] The isolation check valve may also operate in a third
configuration that permits the flow of fluid from both of the
primary and secondary pumps in the third configuration. This can be
achieved, for example, in the configuration shown in FIG. 24B,
where a flap is in a position that permits outward flow from both
flow paths. Depending on the size, shape, and configuration of the
isolation valve, the flow paths, and the flap, this third
configuration can be arranged so that pressure drop at the junction
is minimized or otherwise arranged to allow flow from both pumps
without a substantial pressure drop or flow resistance.
[0183] The various configurations of an isolation valve or a
diverter valve as described herein can provide specific benefits
for a multi-pump system over a system that employs multiple
separate check valves. For example, in a dual pump system with
check valves, the primary pump (e.g., an AC pump) check valve will
typically cycle every time the primary pump runs. This repeated
cycling on and off can cause wear and fatigue to the flappers in
the valves. After time, this wear and fatigue could result in the
flapper and/or the valve failing, thereby giving rise to potential
flooding situations. The presently described isolation/diverter
valves, however, can inhibit these problems by limiting,
inhibiting, delaying, and/or preventing the wear and fatigue on the
flapper mechanism of the valve. For example, as described above,
the isolation valve can be configured so that the flapper moves to
block a flow path when fluid is flowing out of the opposing path.
Because a primary pump may run far more frequently than a secondary
pump, the flapper may be in the same position (e.g., held in place
horizontally like a sewer lid either by gravity and/or water
pressure), continually blocking the secondary flow path even after
the primary pump has cycled on and off multiple times. In this way,
the isolation/diverter valve flapper will not need to move each
time the primary pump turns on and off; it can simply remain in
place. The isolation valve flapper may only need to move away from
its position blocking the secondary flow path when the secondary
pump turns on, which for some pumping systems may be only quite
rare. As such, the flapper of the isolation/diverter valve can
experience far fewer movements than that of a check valve, and
thereby experience much less wear and tear.
[0184] This application also describes sump pump systems that
employ a redundant high water switch. FIG. 25A shows an example of
a sump pump assembly 2500 with a redundant high water switch. FIG.
25B shows the assembly 2500 of FIG. 25A, with a portion of the high
water switch housing 2516 removed to show the internal components
of the high water switch.
[0185] The high water switch 2510 is positioned at a relatively
"high" level, above the pumps, and is configured to activate and
communicate an instruction or otherwise activate functionality of
the assembly 2500 when water rises to or beyond a level that
corresponds to the switch 2510. In this way, the high water switch
2510 serves as a failsafe method for activating the pumping
assembly 2500 if other means configured to activate the assembly
2500 have failed. That is, where water has risen to the level of
the high water switch 2510, it may indicate that one or more pumps
of the pump assembly 2500 (e.g., the primary pump) was not properly
activated, and will default to automatically activate one or both
pumps of the assembly 2500. Additionally and/or alternatively,
activation of the high water switch 2510 may suggest that a single
pump operating is insufficient to keep up with the current pumping
demands. In this way, the high water switch 2510 may be configured
to turn on the secondary or backup pump in addition to the primary
pump when water levels have risen to the height of the switch
2510.
[0186] FIG. 25B shows the internal makeup of the switch 2510 of
FIG. 25A, and demonstrates the redundancy features of such a
device. The switch 2510 includes a lower float 2512 and a
secondary, or higher float 2514. Each float 2512 and 2514 are
configured to float on water. The high water switch 2510 is
configured so that when the lower float 2512 rises to a certain
level above a resting position, for example, because water level
has risen to that level, the switch 2510 will activate, thereby
effecting functionality of the pump assembly 2500 (e.g., turning on
the backup pump). The higher float 2514 serves as a redundant or
backup float in the situation where the lower float 2512 fails to
operate properly. Additionally and/or alternatively, the higher
float 2514 can also be configured to operate as a secondary switch
that executes additional or different functionality even when the
lower float 2512 operates properly. For example, when the lower
float 2512 is activated, the pump assembly 2500 may be configured
to activate a backup or secondary pump. When the higher float 2514
is activated, the pump assembly 2500 may be configured to operate
one or both pumps at a higher rate, to communicate with another
system (e.g., a second backup pumping system) to begin to operate,
or to execute a communication device to generate a warning or
otherwise transmit a signal to a user.
[0187] The redundant high water switch 2510 of FIGS. 25A and B are
shown in a housing 2516 that surrounds two floats 2512 and 2514
that serve as the activating mechanisms of the redundant switch
2512. In other examples, a redundant high water switch may include
other types of switches (e.g., pressure switches, water detection
switches) that operate in a similar fashion.
[0188] The present application also describes pump assemblies that
include a strap handle for ease of transporting the assemblies,
and/or for lowering the assemblies into a reservoir such as a sump
pit. FIG. 26 shows a configuration of a dual pump assembly 2600
incorporating a strap handle 2602 in addition to other features.
The assembly 2600 includes a first pump 2620 (which may be an AC
powered pump) associated with a first volute 2610 and a second pump
2530 (which may be a DC powered pump) associated with a second
volute 2612. The two pumps/volutes are cuffed together by a bracket
2660, which cuffs a discharge portion from each of the two pump
volutes 2610 and 2612.
[0189] The discharge portions are each connected to an isolation
discharge unit 2650, which includes two outlet flow paths 2651 and
2652 connected to fluid outlets of each pump, and a discharge flow
path 2653. This isolation discharge unit 2650 may be or may include
any of the isolation check valves described above. In FIG. 26, the
isolation discharge unit 2650 includes a straight outlet flow
portion 2652 and a curved outlet flow portion 2651. In this Figure,
the straight portion 2652 is connected to the secondary pump 2630,
thereby providing lower flow resistance in the discharge path of
the secondary pump 2630, which may operate under DC power. 2600 may
be removed or replaced out. The assembly also includes a high water
switch 2670, which may be similar to, and operate in a similar
manner to the redundant high water switch 2510 described above and
depicted with respect to FIGS. 25A and B.
[0190] The assembly 2600 includes a strap handle 2602, which
extends over the isolation discharge unit 2650, thereby allowing
the entire assembly 2600, including the isolation discharge unit
2650, to be carried as a single assembly. The strap handle 2602 can
be made from a flexible material to allow the handle to be easily
gripped, without making the footprint of the assembly 2600 larger.
In some examples, the handle 2602 may be formed from a fabric or
woven cloth material, a plastic or fiber-based material, or a
rubber. The strap handle may be fastened to the tops of the pumps
by way of snaps, buttons, rivets, buckles, or other fasteners,
stitching or adhesives, or the handle 2602 may be wrapped around
bars or other components of the pump assembly 2600. In some
aspects, the strap handle may be removable so that certain
components of the assembly can be more easily removed or replaced.
The strap handle 2602 of FIG. 23 can be used in connection with, or
instead of the handles 140 shown in the embodiment of FIG. 1A,
which are shown as bar-type handles that may have a more rigid
construction.
[0191] The present application also provides examples of a battery
management system, and related methods, that allows for pumping
systems and the control modules to be effectively controlled and
operated by a battery or other finite electrical power source. The
system facilitates evaluation of the power levels of the batteries,
and may determine whether a battery should be charged, replaced,
and/or repaired. The battery evaluation system can operate
differently depending on the way the battery is being used. In one
example, the battery evaluation system can be set up based on a 75
amp-hour deep cycle lead acid battery.
[0192] The system may evaluate the charge status of the battery,
but it can also evaluate the condition or general health of the
battery. For example, as a battery ages, its health will likely
deteriorate. Accordingly, a fully charged 8-year old battery will
likely not be as useful as a fully charged brand new battery. This
is a function of wear and tear and general chemical decomposition
of the battery and its components.
[0193] When a pumping system is installed, the evaluation system
can be configured to operate under an assumption that a new battery
is installed and used. Accordingly, a processing unit of the system
can be configured to form calculations based on an initial
assumption of a new battery, whereas additional uses and tests on
the battery will be able to consult with measurements recorded on
the battery in previously maintained situations.
[0194] A first step for evaluation may be to charge the battery to
max capacity, for example, the first step may involve charging the
battery for at least 24 hours. After charging, the battery may be
allowed to settle for a certain time period (e.g., about six hours)
allowing for the removal of excess charge that occurs from the
charging process. The evaluation system can then take a voltage
measurement with a simulated motor load. Via the processing device
(e.g., a computer processor), the voltages measured may then be
stored in a database and compared to other data which may be stored
in the database. The comparison can yield information about the
health and age of the battery.
[0195] For example, the evaluation system may compare voltage
measurement taken at time X, where X=2 years after the original
measurement on a new battery. The evaluation system can then
compare this voltage measurement with the information in the
database, which may include previous measurements of the battery
under test, or other data for reference. Based on the currently
measured voltage across the fully charged battery, and the other
measurements or information in the database, the system can
determine the health or capacity of the battery.
[0196] Based on the comparison results, the processor may cause a
display to present an indicator showing the status of the battery.
For example, the processing device may cause a particular LED
indicator or set of LED indicators to operate in a particular
manner so as to indicate the battery life level. For example, a
brand new battery may light an LED associated with a "Good"
indicator, whereas a partially used battery (e.g., a battery that
has been used for a few years), may light an LED associated with an
"OK" indicator. An even further used battery toward the end of its
life may light an LED associated with "Poor" and a weaker battery
still may light an LED associated with a "Replace" or "Dead"
indicator. An example of a display unit that provides the battery
health information is shown in the remote display panel 2800 of
FIG. 28. In the panel 2800, the series 2820 of LED indicators
associated are associated with LED lights that indicate the "Good,"
OK," "Poor," or "Replace" status of the battery being
evaluated.
[0197] In some forms, the processing device may display the battery
level via a display interface, for example, via a display screen
that provides the battery level as a percentage, or that presents
descriptive terms (e.g., "Good," "OK," "Poor," "Replace," etc.).
And in some embodiments, the processing device may operate in
connection with an audible alarm that generates an audio signal
instead of, or in addition to the generation of these visual
indicators.
[0198] As a battery ages (e.g., over a period time, such as a few
years), the voltages measured under load will reflect lower voltage
values as a result of the chemical characteristics of the battery
degrading. The battery evaluation system is thus configured to
perform repeated periodic voltage measurements. For example,
measurements may be repeated about once a month, but in some
situations depending on the type of battery and the battery's age,
this measurement can be taken more or less frequently. In some
forms, this involves subjecting the batter to a load to test
battery parameters; however, in a preferred form, the system will
use a load-free or no load battery test. For example, in one form,
the system is set up based on a seventy-five amp-hour deep
discharge lead acid battery. When a system is installed the unit
assumes that a new battery is installed. The system's first step is
to charge the battery for 24 hours. The battery is then allowed to
settle for six hours to remove excess charge from the charging
process. An open circuit voltage measurement is made. The voltages
measured are compared to stored data and a battery health LED is
illuminated to show the status of the battery. In one form, the
system will signal the following: [0199] a new battery will
illuminate a >4 Hr LED; [0200] a worn batter (e.g., a battery
that is a few years old) will illuminate a 2-4 Hr. LED; [0201] a
well-used battery (one considered more used than a worn battery)
will illuminate a 1-2 Hr. LED; and [0202] a weak battery (one more
worn than a well-used battery) will illuminate the REPLACE LED.
[0203] As the battery ages, over a period of years, the measured
open circuit voltages will reflect lower voltages as the chemical
characteristics of the battery degrade. In a preferred form, the
battery voltage measurement is repeated once a month. The battery
must meet the "fully charged" criteria (>13.9V & <0.75 A)
before the measurement is performed. The capacity of a fully
charged battery is shown by illuminating an LED scale. Charging is
done automatically when the pump is not running and charge current
is adjusted so as not to damage the battery. When the DC pump is
run, the control measures the current used and the amount of time
the motor runs. Amp-hours consumed are calculated. The amp-hours
used are compared to the latest battery health capacity
measurement. An estimate of projected run time is made and the
appropriate run time LED is illuminated according to the above. As
a depleted battery is being charged, the control keeps track of the
charge being added to the battery so the status of available run
time is current. In a preferred form, a newer battery, fully
charged, will show 6 hours or more run time. A poor battery fully
charged may only show 1-2 hours and a newer battery will likely be
needed after 4-5 hours of use of a poor battery.
[0204] As noted, it can be most efficient if the voltage
measurements are taken on batteries that are fully charged (e.g.,
the battery has been charged for at least 24 hours before
performing the measurement). The capacity of the battery can be
shown by a different indicator that indicates the battery life
(e.g., see interface 2810 in FIG. 28). The evaluation system can
also be configured to automatically charge a pump when it is not
running. The system can also be configured to change the current,
or allow a user to change the current so that the battery does not
become damaged.
[0205] When a DC operated pump is running, certain features of the
evaluation system can be used to measure the current used and the
amount of time that the pump motor is running. In this way, the
evaluation system can calculate and store information pertaining to
the amp-hours used by the pump. This value of amp-hours used can be
compared to the latest battery health capacity measurement values.
Based on this calculated value, the evaluation system can estimate
the projected run time of the pump and communicate a value to a
user, for example, by lighting a particular LED, displaying
information on an interface, sounding an alarm, generating a
notification, or other similar techniques. The calculated value can
represent, for example, the expected run time of the battery
operating at its current rate without the need for further
charging. As a depleted battery is being charged, a control for the
evaluation system can keep track of the charge being added to the
battery and update the current run time of the battery
accordingly.
[0206] In some examples, a new battery, fully charged will show a
run time of 6 or more hours. An older battery showing a poor
status, even when fully charged may only show a run time of 1-2
hours. In some examples, the newer battery, after operating for 4-5
hours, may still show 1-2 hours of available run time. The panel
2800 of FIG. 28 also includes a display 2810 that provides
information pertaining to the current anticipated run time of the
battery. In the panel 2800, the series 2810 of LED indicators
associated are associated with LED lights that indicate the
anticipated run time of a pump operating under current operating
conditions based on the current status of the battery. The
calculated run time can be based on features such as the current
operating rate of the pump, the health of the battery, and the
current charge level of the battery, for example.
[0207] FIG. 27A shows a dual pump assembly 2700 with two pumps 2701
and 2702, an air switch 2720 and a one-piece discharge pipe 2710.
The air switch 2720 includes a pressure tube housing that attaches
to the pump assembly about an exterior side of one of the pumps.
The air switch can be or can include the air switch depicted in
FIG. 18 and described above. The one-piece discharge pipe 2710 can
be, or can include the isolation valves or discharge units
described above with respect to FIGS. 21-24D and 26. For example,
the assembly 2700 may include a one-piece discharge pipe unit that
includes the straight shot portion and the curved portion
specifically depicted in FIGS. 23 and 26. In other examples. By
employing a one-piece unit 2710, the assembly 2700 is "site ready"
for a quick and easy installation. That is, the assembly 2700 can
be configured to hook up to a discharge pipe at a single location
(e.g., via the discharge outlet 2730).
[0208] In the embodiment of FIG. 27A, the two pumps 2701 and 2702
are cuffed together via a bracket 2715, which can operate in manner
similar to that of bracket 1610 shown with respect to FIGS. 16A and
B, albeit with a different configuration. The bracket 2715 is shown
in more detail in FIG. 27B, separate from the pump assembly 2700.
In this example, the bracket 2715 includes opposing annular
portions 2712 and 2714 configured to surround collars of the two
pumps 2701 and 2701, thereby embracing or "handcuffing" the two
pumps together. The bracket 2715 is shown to have a bridge
configuration with a rounded or domed raised portion 2735 between
the two annular ends 2712 and 2714. Offset from one of the annular
portions 2714 is a pressure tube housing support 2712, which is
used to support the pressure tube housing of the air switch 2720,
as shown in FIG. 27A. In some forms, the pressure tube housing may
have the configuration of the housing 1820 shown in FIG. 1820,
whereby the housing 1820 attaches to the housing support 2712 by
way the connection mechanism 1825.
[0209] FIG. 28 shows a remote display panel 2800 for a pumping
system. The panel 2800 provides system status and water level
information as it pertains to a pump assembly. The panel 2800
includes a variety of LED lights that are associated with
indicators. For example, the panel 2800 includes a battery charge
level section 2810, which includes a series of LED lights that are
associated with indicators related to the "Hours of Protection."
These indicators may work in conjunction with the battery
evaluation system described above. As the pump continues to draw
power from the battery and the charge diminishes, the panel 2800
will light different LED lights in the Hours of Protection section
2810 to correspond with the currently calculated expected battery
run time.
[0210] The panel 2800 also includes a section 2820 configured to
display the health of the battery. The series 2820 of LED
indicators associated are associated with LED lights that indicate
the "Good," OK," "Poor," or "Replace" status of the battery being
evaluated. As described above, this battery health level is
different from, the battery charge status level indicated in
section 2810, but may be used as a basis for determining the hours
of protection displayed in section 2810.
[0211] The battery health level can be monitored, as described
above, by periodically performing a series of steps that include:
(1) charging the battery for a predetermined minimum time period is
sufficient to fully charge the battery; (2) measuring a voltage
across the battery (e.g., via a simulated motor load); (3)
comparing, with a processor, the measured voltage with information
in the data store; (4) calculating the battery health value based
on the comparison of the measured voltage with the information in
the data store; and (5) generating a signal via the interface 2820
that indicates the battery health value.
[0212] The data store can be an electronic storage device that is
in communication with the panel 2800 or other components of the
related pump assembly. The data store can include pre-loaded
information, such as a look-up table, that corresponds a voltage
reading with a particular battery health level. The data store can
also be periodically updated with measurements taken according to
the periodically performed method, so that the battery health level
is based at least in part on the measured voltage for that battery
during previously performed measurements. The battery charge value
may be configured to approximate a length of time that a pump can
operate on the power provided current battery without further
charging.
[0213] As noted above, the battery health level can be used as a
part of the calculation to determine the hours of operation
displayed in interface area 2810. For example, a brand new battery
having a "Good" health level that is determined to be half-way
depleted of charge may display an LED associated with the indicator
associated with 2-4 hours. Conversely, an older battery having a
"Poor" health level may indicate only a 1-2 hour level when the
battery is determined to be fully charged.
[0214] The panel 2800 also includes a display area 2830 that
provides information pertaining to the water level in the basin. In
this region 2830, the panel will light up a certain LED light or
series of LED lights to indicate the amount of water currently in
the basin or pump associated with the pump assembly. Using sensors
associated with the pump assembly (including a number of the
sensors described herein), the panel 2800 will determine a detected
water level, and generate a display on interface region 2830 that
presents that water level to a user.
[0215] The display panel 2800 may also include a power/status
section 2840 that identifies which pumps, if any, of the pump
system are currently operating. For example, the LED associated
with the "Primary Pump" indicator will light if the primary pump of
the system is operating, the LED associated with the "Backup Pump"
indicator will light if the backup pump of the system is operating,
and an LED associated with a "Turbo Mode" indicator may light if
both pumps are operating. In some examples, a user may be able to
control which pumps are operating via the panel 2800, for example,
by activating buttons or other input mechanisms.
[0216] The display panel 2800 also includes a variety of functional
operators, which can be a push-button feature that generates
functionality when pressed by a user. In particular, panel 2800
includes a test operator 2850, which generates a test to assure
that the system is operating properly when pressed. In some
configurations, the panel 2800 or other objects associated with the
panel 2800 may be configured to generate audible sounds and
warnings, as described herein. Accordingly, the panel 2800 also
includes a mute operator 2860, which can be configured to silence
or mute all audible sounds when activated by a user.
[0217] FIG. 29A is a top view of an integrated pump controller 2900
that operates a battery management system as described above. The
controller may 2900 may be attached to, or rest upon a power
supply, such as a battery or other DC power source that supplies
backup power to a pumping system. The controller 2900 may also
include a louvered portion 2910 that allows air to flow to the
processing equipment, which can help prevent the control unit from
overheating.
[0218] As shown in FIG. 29A, the controller 2900 includes an
operating interface with a series of operators that can be
configured to execute a variety of different functions. For
example, the interface can include a reverse battery indicator 2912
that alerts users when the battery is connected to the system wrong
or backwards. If the battery is accidently connected wrong (e.g.,
with the wrong polarity), then the reverse battery (or incorrect
battery connection) indicator 2912 is displayed. While in the
preferred embodiment this incorrect battery connection signal 2912
includes a displayed signal, such as a light, it should be
understood that in alternate embodiments the reverse battery
indicator may include (in addition to or in lieu of the visual
display) an audible alarm to warn the user the connection is
incorrect (preferably immediately).
[0219] A battery test/safety reset operator 2914 can perform a test
on the battery, for example, determining a current state or health
level of the battery and display that value on the interface. The
battery test/safety reset operator 2914 can also be configured to
perform a safety reset of the pumping system. For example, when a
tripping deice determines that a thermal load on a portion of the
circuit has exceeded a safe operating temperature and trips the
circuit, the safety reset button can be operated to reactivate the
circuit (e.g., reset may reset the thermal overload protector).
[0220] A mute operator 2916 can be configured to silence all
audible alarms generated by the controller 2900 or associated
units. In some examples, the mute operator can be pressed in
advance of an alarm sounding and can have the effect of silencing
all alarms that may potentially sound within a given time period.
For instance, if a user will be working on or around the controller
2900 for a certain time period and wishes not to be distracted by
an alarm, the user may press the mute operator 2916 to deactivate
or mute all audible alarms in advance for a predetermined time
period. The mute operator 2916 may serve to mute all alarms for a
predetermined time period with each press. For example, the
controller 2900 may be configured so that one press of the mute
operator 2916 will serve to mute all alarms for one hour. The
controller 2900 may allow the mute operator 2916 to be pressed
multiple times to extend the muted period as desired by the user.
For example, the controller 2900 may be configured to allow the
mute operator 2916 up to eight times to mute all alarms in advance
for up to eight hours.
[0221] The display interface may also include the system test
operator 2918, which can be configured to effect the performance a
test on the pump system to assure that certain features of the
system are able to operate as expected. The system test can be
configured to operate the primary pump and the backup pump to
ensure that the pumps turn on and operate as expected, and that
there are no clogs or other obstructions.
[0222] The control unit 2900 also may be connected to a display
panel, such as panel 2800 as shown with respect to FIG. 28. In
other embodiments, rather than (or in addition to) being connected
to a display panel, the controller 2900 may communicate wirelessly
with a remote device or series of devices to provide the
information that could be displayed on the panel. For example, the
controller 2900 may communicate with a mobile electronic device
(e.g., a smart phone, tablet computer) or other computing device
via the Internet, a wireless network, or a cellular network. The
device can operate an application that will allow the user to
receive information and affect control functionality that may
otherwise be available via the display panel (e.g., panel 2800). In
some forms, the remote device operating the application may be
capable of performing additional functionality and displaying
additional information beyond that available by a panel.
[0223] FIG. 29B is a rear view of the integrated pump controller
2900 and battery management system of FIG. 29A. As shown, the
controller 2900 includes a variety of connection ports that allow a
user to connect a variety of components to the controller. For
instance, the controller of FIG. 29B is shown having an AC power in
cord 2920 that provides AC power to the controller, for example,
via a 120-volt AC outlet or the like. The controller 2900 also
includes a power supply line 2921 that delivers electrical power
from a battery associated with the controller 2900 to a DC powered
device, such as a DC powered sump pump. An AC powered line 2922
provides AC electrical power to another electrically powered
device, such as an AC powered sump pump. A remote display line 2923
forms a communication line between the controller 2900 and a
display panel, such as panel 2800 shown in FIGS. 28 and 29A. An air
switch line 2925 communicates with an air switch associated with
the pumping system and facilitates the controller 2900 to effect,
cease, or modify the operation status of the pumps of the pumping
system. The backup float switch line 2924 communicates with the
controller and serves as a redundant backup to assure that the pump
operates as desired even where issues may arise with other primary
sensors or operating equipment.
[0224] FIGS. 32A and 32B provide another embodiment of a
controller/battery assembly 3200 that can be used in connection
with a variety of the pumping systems described herein. The
assembly 3200 includes a battery 3202 or DC power supply, which can
be stored, for example, in a battery housing. A controller 3201
rests upon the battery 3202, and may be attached or attachable
thereto. The controller 3201 has a connection panel 3210 that
allows the assembly 3200 to connect and communicate with various
equipment of the pumping system.
[0225] FIG. 32B shows a head on view of the panel 3210 of the
pumping system. The panel 3210 comprises a variety of outlets for
attachments to various sensors and devices. A 120-volt AC input
3211 allows the controller 3200 to receive electrical power from an
AC power source, which AC power can be used to charge the battery
3202. An AC pump outlet 3224 allows an electrical cable to connect
with an electrical device (e.g., an AC powered pump) and provide AC
power to the device. In some formats, the AC pump outlet 3224 may
provide up to four amps of electrical current. A DC pump power
outlet 3214 provides DC electrical power from the battery 3202 to a
DC powered pump, such as a 12-volt DC pump, which may serve as a
backup pump to the pumping system.
[0226] The panel 3210 also includes a security alarm port 3212,
which can connect to one of various security devices including
speakers or sound generating equipment, lights or display
equipment, and/or communication devices that can send security
signals to other remote devices (e.g., text messages). The panel
3210 may also include a speaker and/or audible alarm system that
generates warning sounds in the event of certain detected events
(e.g., high water warnings, pumps not operating, battery level low,
etc.) In this manner, the panel 3210 may include a mute button
3218, which serves to silence any such alarm, and a test button
3219, which allows the user to test the alarm signal to ensure that
it is operating properly.
[0227] The panel 3210 may also comprise one or more DC pump fuses,
including a primary DC pump fuse 3215 and a spare or backup DC pump
fuse 3213. Communication ports 3216 allow the controller 3201 to
communicate with various display equipment, such as display panels,
monitors, or other interfaces. The communication ports 3216 may
also enable communication with other equipment or communication
devices, such as an internet router, a telephone line, a cellular
network, or the like. The panel 3210 may include ports for
connecting to various sensors, such as a water sensor port 3223
that communicates with a sensor that monitors the water level in a
sump pit, and a back-up float switch port 3222 that communicates
with a backup float switch that serves as a redundant switch to any
float switches associated with the pumps of the pumping system.
Vent holes 3221 on the panel 3210 allow for air flow into the
controller 3201, which helps inhibit overheating. The panel 3210
may also include a warning system that includes a reverse polarity
warning light 3217, which may light up or blink when polarity
between the battery and the controller and/or pumping systems is
not configured properly, thereby warning the user to correct the
issue before initiating the supply of power.
[0228] Examples described in this application may utilize various
techniques for controlling operation of the pumping devices. For
instance, sump pump water level can be controlled by a float
activated switch. As the water level in the sump rises to a
predetermined level, a floating device imposes a change in the
state of an electric switch, which switch in turn activates a pump
to remove water and reduce the water to a lower level. This level
control is normally achieved through hysteresis built into the
float mechanism. Many sump pump failures can be traced to a failure
of the switch. Accordingly, some aspects described herein relate to
an electronic tilt switch that can be used in lieu of a float
switch or other device.
[0229] The electronic tilt switch utilizes high volume
accelerometer technology, such as those used in portable electronic
devices, to create a switch that can control the operation of the
pumping system. An example of such an electronic tilt switch is
shown in FIGS. 30A and 30B. In FIG. 30A, the tilt switch 3000 takes
advantage of a 3-axis accelerometer of the sort that may be used in
smart phones or other similar devices. The tilt sensor 3000 can be
secured to a fixed structure, such as discharge pipe 3050. The tilt
switch 3000 includes a float 3020 and a hinged housing 3010. The
float 3020 has an accelerometer, which can be located, for example,
within a cavity 3022 of the float. The accelerometer is used
measure the tilt angle of the float. Thus, when the water level
within the sump rises to the level of the tilt sensor 3000, the
float 3020 will rotate with respect to the hinge 3010, and the
accelerometer will detect a change, and communicate with a remote
circuit board via a cable 3060, or another communication mode
(e.g., wireless communication). The supporting circuit board can be
located remote to the tilt sensor 3000. That is, in some
embodiments, the accelerometer may be in the float 3020, and the
remaining supporting circuitry is located remote from the
accelerometer, such as in a control unit.
[0230] FIG. 30B shows the tilt switch 3000 from a rear view, where
the float 3020 is at its highest position, having pivoted about the
hinge 3010. In this view, the water level in the sump has risen
beyond the location of the tilt switch 3000, thereby causing the
float 3020 to pivot upwards by an angle .theta.. The tilt switch
and/or the supporting circuitry (which may be within or remote to
the tilt switch) can be configured to effect operation of a pumping
device when the accelerometer detects that the float has pivoted by
an angle .theta., thereby representing a predetermined water level
in a sump pit.
[0231] FIG. 31 shows an example set up of a sump system 3100
utilizing the tilt switch 3000 with an accelerometer of FIGS. 30A
and B. The system 3100 includes a sump pump 3110 within a sump
3105, supplied with electrical power via a power cord 3115. The
tilt switch 3000 is attached to a discharge outlet 3150. The tilt
switch 3000 communicates with a control box 3120 via the power cord
3060. The control box 3120, powered via a power cord 3125, can
include the various power switching electronics, which can include
a single load driving output, such as a triac, a zero crossing
device, micro-processor transformers/dropping resistors, a diode
bridge, or the like, within a housing. In some examples, the
control box 3120 may include or be with associated LED's, alarms,
and possible telephone dialer that provide notifications to a user.
With a single electronic tilt switch 3000 the water level will be
detected by a predetermined angle .theta., as measured by the
accelerometer and related equipment inside the tilt switch housing
3010.
[0232] In one example of operation, when the tilt sensor 3000, via
the accelerometer, detects a level change that is greater than a
predetermined value (e.g., angle .theta.), the accelerometer will
communicate to the control box 3120 to change the state of the
triac, thereby effecting operation of the pump 3110. As the water
level in the sump pit 3105 drops, the angle .theta. will be
monitored by the accelerometer. The change in the angle .theta.
over to time can be calculated by a microprocessor within the
control box 3120 to establish an appropriate off level for the
pump. In some configurations, if the triac can be configured to
activate an alarm function to notify a user if the water level does
not drop at a predetermined rate, or to a certain level within a
predetermined time. In some forms, the system can be configured to
activate a second alarm function if the water level continues to
rise. For purposes of redundancy or for controlling additional
pumps multiple electronic tilt switches could be employed.
[0233] Various embodiments described herein include cords that
supply electrical power to the pump assembly. The cords may serve
to provide AC power to an AC pump, or to provide a charge to a
battery of a DC pump, or to connect a DC pump to a battery. In some
examples, the various cords of the assembly will be configured so
that all cords form the same length. This cord length matching
provides users with assurance that a device is installed properly.
Some examples of the pump assembly will include cord management
systems that facilitate winding or wrapping of cords around the
pump assembly or other objects associated with the assembly. The
cord management systems may include spring or motor driven cord
retraction mechanisms that facilitate winding of the cord about the
pump.
[0234] Certain examples described herein describe pumps that
utilize top suction functionality. That is, the pumps draw in fluid
to be pumped from an upper location (e.g., above the volute), and
draw in the fluid downward rather than by sucking the fluid upward
through a bottom portion of the pump (e.g., from below the volute).
This top suction functionality creates a self-venting feature that
inhibits air-locking problems that can occur in bottom suction
devices. As a result, the top suction functionality allows for the
pumping apparatus to operate without applying vent holes in the
discharge pipe (which is often necessary for bottom suction
devices), or other venting mechanisms.
[0235] The presently described technology has several applications
for use. For example, the presently described systems and
applications can be used in residential sump pits (which are
employed in a majority of homes with basements); in rental
properties (where the tenants may not be aware of the sump system);
in vacation homes (where the occupants may not be present during a
high water event); and/or in other locations where rising water
could cause damage (crawl spaces, stair wells, etc.).
[0236] The present disclosure presents embodiments of tandem sump
pump assemblies that refer to primary and secondary pumps. In some
aspects the primary pump will be an AC powered pump and the
secondary pump will be DC powered. However, in some embodiments
both pumps will be AC powered, and in other aspects, both pumps
could be DC powered. Depending on the intended use, all embodiments
described herein, and all references to AC pumps and/or DC pumps
could be substituted for an AC/DC pump unless the context makes
clear otherwise.
[0237] Thus, in view of the above disclosure, it should be
understood that numerous concepts are disclosed herein and intended
to be covered herein. For example, in one form and as shown in
final FIG. 33, a back-up pump system is disclosed having a primary
AC pump and a secondary DC pump, with the primary AC pump having a
primary switch for operating at least one of the pumps (e.g., a
solid state switch), and the secondary DC pump having a secondary
switch for operating at least one of the pumps. We have used
similar numbering to that show in FIGS. 1A-G, 16A-B, and 18, but
adding the prefix 33 to distinguish one embodiment from the others.
The system includes a back-up battery for powering the secondary DC
pump when regular power conditions are interrupted (e.g., power
outages, unplugged AC cord, other loss of mains power supply,
etc.). A primary controller is electrically connected to the pumps
for operating same, and a secondary controller, discrete from the
primary controller, and electrically connected to at least one of
the pumps to operate the at least one of the pumps when the primary
controller malfunctions or fails.
[0238] In some forms, the solid state primary switch may include a
pneumatic pressure transducer sensor that utilizes pressure
differentials to determine when one or more of the pumps should be
operated. The primary controller may also include a processor
programmed to activate the primary AC pump when the pneumatic
pressure transducer indicates that a threshold fluid level has been
reached. The processor may be programed to activate the secondary
DC pump when the regular power conditions are interrupted and when
the threshold fluid level has been reached. In addition or even
alternatively, the processor may be programmed to activate the
secondary DC pump when the primary AC pump is not lowering the
fluid level at a sufficient rate or in a sufficient amount of time.
In some forms, the primary controller will include a processor
programmed to perform a battery health check.
[0239] As mentioned above, some embodiments will have a battery
charging circuit electrically connected to the back-up battery for
charging the battery and regular power conditions are present, and
having a battery health monitoring circuit for monitoring battery
health. The battery health monitoring circuit may include a display
for displaying indicia indicative of the battery health and an
alarm for alerting a user to a problem with the battery based on
the monitored battery health. The term alarm is used broadly to
mean any type of audible alarm (buzzer, speaker, siren, etc.),
visual alarm (e.g., light, flag, display, etc.) and/or an
electronic message alarm (e.g., text, app notification, auto-call
or voice message, etc.). Similarly, the term display is used
broadly to mean any type of light, digital display (e.g., LED
display, LCD display, touch screen, plasma display, numeric
display, etc.), analog display, and/or a mechanical indicator
(e.g., flag, indicator, etc.).
[0240] In a preferred form, the primary controller includes a
communication device for transmitting notifications about the pump
system to a user. The communication device may include a
transmitter or transceiver for connecting the primary controller to
a wireless network to transmit the notification via the network. A
transceiver is preferable to allow two-way communication and user
interaction with the pump system to get information from the pump
system (e.g., real-time status, diagnostic analysis, historical
data, such as performance data, etc.).
[0241] In some forms, the pumps system is connected to a discharge
pipe via one or more check valves. However, in other forms, the
primary AC pump and secondary DC pump are connected to a diverter
valve that diverts fluid flowing from one of the pumps toward a
discharge pipe that the pump system is connected to and hinders
fluid from backflowing or recirculating back into the other pump
(e.g., the diverter prevents one pump from pumping fluid back or
backwards into the other pump to prevent flooding, etc.). In a
preferred form, the diverter valve includes first and second
inlets, one common outlet and a diverter body positioned between
the inlets, the first inlet being in fluid communication with the
primary AC pump and the second inlet being in fluid communication
with the secondary DC pump, and the diverter body being movable
between: a first position wherein the diverter body blocks the
second inlet and allows fluid to flow from the primary AC pump to
the common outlet while hindering fluid flow into the second inlet;
and a second position wherein the diverter body blocks the first
inlet and allows fluid to flow from the secondary DC pump to the
common outlet while hindering fluid flow into the first inlet. The
first fluid passage extending between the primary AC pump and the
common outlet may include a curve or bend, and the second fluid
passage extending between the secondary DC pump and the common
outlet may form a generally linear fluid passage which allows the
second fluid passage to provide less fluid resistance than the
first fluid passage to allow the secondary DC pump to operate more
efficiently since it is powered by the battery and not an AC power
supply. In some instances it is preferable to have the AC pump side
of the system deal with plumbing bends and turns that cause loss or
greater fluid turbulence and inefficiencies since AC power
seemingly is available for extended periods of time compared to the
DC power provided by a battery (e.g., batteries have battery life
and it is desirable to setup the system to maximize efficiencies
that conserve the battery power life). In the forms illustrated,
the curve or bend of the first fluid passage is between
45.degree.-90.degree. (e.g., the bend in the plumbing or piping
from the AC pump to the outlet pipe) and the second fluid passage
is coaxially aligned with the discharge pipe (e.g., a straight or
straighter shot).
[0242] Also disclosed herein is a pump system having a connector
for connecting the primary AC pump to the secondary DC pump so that
the pumps may be moved or placed together as an assembly. In the
form illustrated in FIG. 33, the connector 33610 is a coupling that
has a first interface 33614 for aligning with a first AC pump 33130
outlet and a second interface 33612 for aligning with a second DC
pump 33120 outlet so that the pumps may be connected to one another
and moved or placed together as an assembly. A raised arch connects
the first and second interfaces 33614, 33612 of the coupling 33610.
The first interface 33614 is connected to the first AC pump outlet
via a first fastener 33631 and the second interface 33612 is
connected to the second DC pump outlet via a second fastener 33630.
The first AC pump outlet and second DC pump outlet each have
internal female pipe threading (FPT) and the first fastener and
second fastener are threaded sleeves each having male pipe
threading (MPT) on one end that mates with the FPT of the first AC
pump outlet and second DC pump outlet, the fasteners further each
having a flange portion that engages respective portions of the
coupling to secure the coupling to the pumps and the pumps to one
another. In the form illustrate in FIG. 33, the flange has flat
edges to form a nut-type threading that a wrench can be used with
and/or engage to tighten the sleeve to the pump and clamp the
coupling between the sleeve and the volute. Seals (e.g., rubber
sealing rings, washers, etc.) may also be sued to improve this
connection. In the form illustrated in FIG. 33, the coupling
further includes a portion for connecting at least a portion of the
pneumatic pressure transducer sensor to in order to position the at
least a portion of the pneumatic pressure transducer in a desired
position in relation to the pumps. The portion protrudes out from
one of the interfaces of the coupling (e.g., 33612) to position a
hollow housing 33820 of the pneumatic pressure transducer sensor
proximate the side wall of one of the pumps (e.g., DC pump
33120).
[0243] In other forms mentioned above, the connector may be a first
mating member connected to the primary AC pump and a second mating
member connected to the secondary DC pump and the first and second
mating members mate with one another to connect the pumps to one
another. For example, the first mating member may be one of a male
or female mating structure and the second mating structure the
other of a female or male mating structure so that the mating
members interconnect with one another to connect the pumps
together. In one earlier form, the volutes were formed with such
structures to interconnect the volutes and, thus, the pumps to one
another.
[0244] The connector may also include other items that also help
connect the pumps to one another. For example, in FIG. 33, the
connector is also a member that extends from a top or side surface
of the primary AC pump to a top or side surface of the secondary DC
pump to connect the pumps together. In the form illustrated, the
member is a handle 33140 that interconnects the pumps so that they
can be carried or placed as a connected assembly. In some forms,
two such handles have been shown made from metal and
interconnecting the top of the pumps. In other forms illustrated
herein, this form of connector has been a fabric strap. Regardless
of its ultimate form or shape, it may be helpful to use multiple
forms of connectors in order to securely connect one pump to the
other so that they travel and place well. For example, having a
first connection between the lower portions of the pumps (e.g., the
pump outlets, e.g., volute outlets) and a second connection between
the upper portions of the pumps (such as the handle interconnecting
the tops of the pumps) helps form a stable connection between the
pumps and one that allows for easy carry and placement. AC power
cord 33104 and DC power cord 33102 are also illustrated in FIG.
33.
[0245] In addition to the above and as illustrated in FIG. 33, the
plumbing or piping of the pumps forms yet another connector that
connects the pumps to one another. This PVC piping forms a
cross-over connection between the two pumps that establishes yet
another connection point or portion between the two pumps. In a
preferred form, the handle will extend over the top of this piping
in order to encourage the connected pump assembly to be carried by
the handle and not the piping or plumbing. In the form illustrated
in FIG. 33, each pump has a check valve connected downstream of the
pump outlets (e.g., volute exits), and preferably downstream of the
coupling that interconnects the volutes. Then the cross-over
plumbing or piping connects the respective check valves to a common
outlet pipe which can be connected to a common discharge pipe of
the system via a simple rubber sleeve connector (or coupling)
connected to the discharge pipe and the common outlet pipe via hose
clamps or the like. The check valves prevent either pump from
pumping fluid backwards into the other pump (e.g., recirculating or
backflowing fluid into the other pump). However, in alternate
embodiments similar to those discussed above, the pump assembly
could be configured with a single isolation valve (e.g., diverter
valve) to be used in lieu of the dual check valve
configuration.
[0246] It should be understood that the embodiments discussed
herein are simply meant as representative examples of how the
concepts disclosed herein may be utilized and that other
system/method/apparatus are contemplated beyond those few examples.
For example, while an AC pump and DC pump system is described as
preferred, it should be understood that this disclosure
contemplates using two AC pumps or two DC pumps, etc. In addition,
it should also be understood that features of one embodiment may be
combined with features of other embodiments to provide yet other
embodiments as desired. Similarly, it should be understood that
while the system/method/apparatus embodiments discussed herein have
focused on sump pump systems, other uses of the solutions presented
herein are contemplated, such as the use of other type of pumping
devices.
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