Note: Descriptions are shown in the official language in which they were submitted.
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TITLE: BATHING UNIT CONTROLLER
Field of the invention
The present invention relates to controllers suitable for use in bathing units
and,
moreparticularly, to controllers having a plurality of connectors for
connection to bathing
unit components.
Background
A bathing unit, such as a spa, typically includes various components such as a
water
holding receptacle, pumps to circulate water in a piping system, a heating
module to heat
the water, a filter system, an air blower, an ozone generator, a lighting
system, and a
control system for activating and managing the various parameters of the
bathing unit
components. Other types of bathing units having similar components include,
for
instance, whirlpools, hot tubs, bathtubs, therapeutic baths, and swimming
pools.
Typically, the control system of a bathing unit includes a controller to which
are
connected the various bathing unit components. The controller is adapted to
control the
power supplied to each one of the connected components. The controller
receives input
signals from various input devices, such as for example a plurality of sensors
that monitor
the various components of the bathing unit and from a control panel allowing a
user to
control various operational settings of these components. In response to the
input signals,
the controller activates, or deactivates, the various bathing unit components
by supplying
power, or ceasing to supply power, to the components.
Usually, different components in a given bathing unit have different operating
power
requirements. For instance, some of the bathing unit components may require to
be
powered by way of a 120 volts (V) AC voltage source, while other bathing unit
components may require to be powered via a 240 volts (V) AC voltage source.
Similarly,
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different bathing unit components may be designed to operate with different
maximum
current draws. The current draw to operate the various bathing unit components
may
range, for example, from 0.1 amps (A) for an ozone generator to 20 amps (A)
for a large
pump. Moreover, the current draw to operate two bathing unit components of a
same
type, such as two pumps or two heating modules, may also be different for the
two
components. For instance, one pump may require a current draw of 12 amps (A)
to
operate, while another pump may require a current draw of 20 amps (A) to
operate.
Figure la shows a sample controller 100 suitable for use in a bathing system.
As
depicted, the controller 100 includes a controller body coupled to a heater
122, the
controller body having an access panel 112 connected thereto. Figure lb shows
the same
controller 100 as figure 1 a with the access panel 112 opened. The controller
body defines
an enclosure in which a control circuit 108 is located. The controller 100
also includes
a set of connectors 102 positioned along the periphery of the controller body
and adapted
for receiving complementary connectors associated to respective bathing unit
components. As depicted, the set of connectors 102 are in communication with
the
control circuit 108 through electric connection wires 110. In use, the control
circuit 108
is adapted for selectively providing electrical power to respective bathing
unit
components connected through the set of connectors 102. A plurality of power
connection elements 106 and fuses 104 are also located with the enclosure
defined by the
controller body. The power connection elements 106 are for coupling the
controller to
an external electrical power source (not shown in the figure).
In order to accommodate bathing unit components having different power
requirements,
each connector in the set of connectors 102 is adapted to supply power to that
particular
component in accordance with its power requirements. To achieve this, each
connector
usually includes a set of electrical contact elements, at which a certain
voltage or current
output will be available. For example, if a bathing unit includes one
component having
operating power requirements of 120 volts (V) and 12 amps (A) and another
component
having operating power requirements of 240 volts (V) and 20 amps (A), the
controller
will thus be configured to include one connector having contact elements at
which an
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output of 120 volts (V) and 12 amps (A) will be available and another
connector having
contact elements at which an output of 240 volts (V) and 20 amps (A) will be
available.
A first deficiency associated to controllers of the type shown in figures la
and lb is that
a bathing unit installer or service technician runs the risk of connecting a
given bathing
unit component to a wrong connector, i.e. to a connector not intended to be
connected to
that given component. For instance, in the above example, the component with
operating
power requirements of 120 volts (V) and 12 amps (A) runs the risk of being
connected
to the controller connector at which an output of 240 volts (V) and 20 amps
(A) will be
available.
Another deficiency associated to controllers of the type shown in figures la
and lb is that
the control circuit 108 is often damaged during servicing by a technician. For
example,
the electric connection wires 110 between the set of connectors 102 and the
control
circuit 108 are often inadvertently disconnected during handling. Similarly,
electrical
components on the control circuit 108 are sometimes damaged when fuses 104 are
replaced or electrical connections established. In addition, since the
controller 100 is
usually positioned in proximity to water, when the access panel 112 is open,
water
sometimes comes into contact with the electronic components contained in the
controller
body and damages those components. Such incidences usually translate into a
greater
number of service calls to the bathing unit vendor (or bathing unit controller
vendor)
which therefor increases the costs of providing bathing unit controllers.
Furthermore,
even though the failure of the bathing unit controller originated from the
technician's
mishandling of the equipment, the result is a perception of lack of
reliability of the
bathing unit controller.
Against the background described above, it appears that there is a need in the
industry to
provide a controller suitable for a bathing unit that alleviates at least in
part the problems
associated with existing controllers.
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Summary
In accordance with a first aspect, the invention provides a controller for use
in controlling
bathing unit components in a bathing unit system. The controller comprises a
controller body
having a back surface, a front surface generally opposed to the back surface
and an enclosure
defining a space between the back surface and the front surface. The front
surface includes a
plurality of connector interfaces, wherein at least some connector interfaces
in the plurality of
connector interfaces are for engaging complementary connectors associated with
respective
bathing unit components. The controller also comprises an electronic circuit
board positioned
at least in part within the enclosure, the electronic circuit board including
a control circuit.
The control circuit is programmed for selectively causing electrical power to
be provided to
respective bathing unit components connected through the at least some
connector interfaces
at least in part based on signals originated from sensors in the bathing unit
system.
In accordance with another aspect, the invention provides a controller for use
in controlling
bathing unit components in a bathing unit system. The controller comprises a
controller body
including a back surface, a front surface generally opposed to the back
surface and an
enclosure defining a space between the back surface and the front surface, the
space including
a first portion having a first content and a second portion having a second
content. The front
surface includes an access panel moveable between a closed position and an
open position for
selectively providing access to the second portion. When in the open position,
the access
panel exposes the second content without exposing the first content. The
controller also
comprises a plurality of connector interfaces positioned on the controller
body, wherein at
least some connector interfaces in the plurality of connector interfaces are
for engaging
complementary connectors associated with respective bathing unit components.
The controller
also comprises an electronic circuit board positioned at least in part within
the enclosure, the
electronic circuit board including a control circuit. The control circuit is
programmed for
selectively causing electrical power to be provided to respective bathing unit
components
connected through the at least some connector interfaces at least in part
based on signals
originated from sensors in the bathing unit system.
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In accordance with another aspect, the invention provides a controller
suitable for use in
controlling bathing unit components in a bathing unit system. The controller
comprises a
controller body and a control circuit positioned within the controller body.
The controller
body has a back surface and a front surface generally opposed to the back
surface, where the
5 front surface includes a plurality of connector interfaces. Each connector
interface is adapted
for receiving a connector associated to a respective bathing unit component.
In use, the
control circuit is adapted for selectively providing electrical power to
respective bathing unit
components connected through the plurality of connector interfaces.
In accordance with a specific example, the control circuit is mounted to an
electronic circuit
board including printed conductor traces. At least one of the connector
interfaces includes a
conductive member establishing a direct contact with the printed conductor
traces. The direct
contact may be established by any suitable way such as, for example, through a
soldered
connection between the printed conductor traces and the conductive member.
In accordance with a specific example of implementation, the controller
further comprises a
set of instructions positioned on the front surface of the controller body.
The set of
instructions provides guidance as to how to couple the plurality of connector
interfaces to
respective connectors associated to bathing unit components.
In accordance with a specific example of implementation, the back surface and
the front
surface are connected such as to form a first portion and a second portion,
where the second
portion may be accessed independently from the first portion. The second
portion includes an
access panel providing access to the second portion. The first portion is
sealed such as to
prevent access thereto by a technician. Optionally, the first portion is
sealed such as to reduce
the likelihood of water entering the first portion.
In accordance with a specific example of implementation, at least some
connector interfaces
include descriptive indicia providing guidance in locating corresponding
connectors
associated to bathing unit components. The descriptive indicia may include
alphanumeric
characters, color indicia or any other suitable form of indicia. In a non-
limiting example, the
I
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color indicia allow effecting connections between the plurality of connector
interfaces and the
connectors associated to bathing unit components on the basis of a color code.
In accordance with another aspect, the invention provides a controller for use
in controlling
bathing unit components in a bathing unit system. The controller comprises a
controller body
including a back surface and a front surface generally opposed to the back
surface. The
controller also comprises a plurality of connector interfaces positioned on
the controller body,
each connector interface of the plurality of connector interfaces being
adapted for receiving a
connector associated to a respective bathing unit component. The controller
also comprises a
set of instructions positioned on the front surface of the controller body,
the set of instructions
providing guidance as to how to couple the plurality of connector interfaces
to respective
connectors associated to bathing unit components. The controller also
comprises a control
circuit positioned within the controller body. In use the control circuit is
adapted for
selectively providing electrical power to respective bathing unit components
connected
through the plurality of connector interfaces.
In accordance with a specific implementation, at least some of the plurality
of connector
interfaces are positioned on the front surface of the controller body. In
accordance with a
non-limiting example of implementation, at least some of the plurality of
connector interfaces
are positioned on the periphery of the controller body.
In accordance with yet another aspect, the invention provides a controller for
use in
controlling bathing unit components in a bathing unit system. The controller
comprises a
controller body, a plurality of connector interfaces positioned on the
controller body and a
control circuit. The controller body includes a first portion and a second
portion, wherein the
second portion may be accessed independently from the first portion. Each
connector
interface of the plurality of connector interfaces is adapted for receiving a
connector
associated to a respective bathing unit component. In use the control circuit
being adapted for
selectively providing electrical power to respective bathing unit components
connected
through the plurality of connector interfaces.
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6a
In accordance with a specific implementation, the second portion includes an
access panel
providing access to the second portion. The first portion is sealed such as to
prevent access
thereto by a technician. Optionally, the first portion is sealed such as to
reduce the likelihood
of water entering the first portion.
In accordance with yet another aspect, the invention provides a controller for
use in
controlling bathing unit components in a bathing unit system. The controller
comprises a
controller body, a plurality of connector interfaces positioned on the
controller body and a
control circuit. Each connector interface of the plurality of connector
interfaces is adapted for
receiving a connector associated to a respective bathing unit component. At
least some
connector interfaces of the plurality of connector interfaces include
descriptive indicia
providing guidance in locating corresponding connectors associated to bathing
unit
components. In use the control circuit is adapted for selectively providing
electrical power to
respective bathing unit components connected through the plurality of
connector interfaces.
In accordance with a specific implementation, the controller body includes a
back surface and
a front surface generally opposed to the back surface, the plurality of
connector interfaces
being positioned on the front surface of the controller body.
These and other aspects and features of the present invention will now become
apparent to
those of ordinary skill in the art upon review of the following description of
specific
embodiments of the invention in conjunction with the accompanying drawings.
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Brief description of the drawings
A detailed description of the embodiments of the present invention is provided
herein
below, by way of example only, with reference to the accompanying drawings, in
which:
Figures la and lb show schematic representations of a prior art bathing unit
controller;
Figure 2 shows a block diagram of a spa system equipped with a bathing unit
controller
in accordance with a specific example of implementation of the present
invention;
Figure 3a shows a bathing controller suitable for use in the spa system shown
in figure
2 in accordance with a specific example of implementation of the present
invention;
Figure 3b shows the bathing controller shown in figure 3a with an open access
panel
showing a terminal block in accordance with a specific example of
implementation of the
present invention;
Figure 3c shows the back surface of the bathing controller depicted in figure
3a in
accordance with a specific example of implementation of the present invention;
Figure 3d shows the bathing controller shown in figure 3a showing a first
portion and a
second portion in accordance with a specific example of implementation of the
present
invention;
Figure 4 shows the bathing controller shown in figure 3 a with connectors
associated to
respective bathing unit components connected thereto in accordance with a
specific
example of implementation of the present invention;
Figure 5 shows the bathing controller shown in figure 3b showing the terminal
block
having a set of electrical wires connected thereto in accordance with a
specific example
of implementation of the present invention;
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Figure 6 shows a portion of an electronic circuit board a connector interface
and a
connector in accordance with a specific embodiment of the present invention.
In the drawings, the embodiments of the invention are illustrated by way of
examples. It
is to be expressly understood that the description and drawings are only for
the purpose
of illustration and are an aid for understanding. They are not intended to be
a definition
of the limits of the invention.
Detailed Description
The description below is directed to a specific implementation of the
invention in the
context of a spa system. It is to be understood that the term "spa system", as
used for the
purposes of the present description, refers to spas, whirlpools, hot tubs,
bathtubs,
therapeutic baths, swimming pools and any other type of bathing unit that can
be
equipped with a control system for controlling various operational settings.
Figure 2 illustrates a block diagram of a spa system 10 in accordance with a
specific
example of implementation. The spa system 10 includes a spa receptacle 18 for
holding
water, a plurality of jets 20, a set of drains 22 and a control system. In the
non-limiting
embodiment shown, the control system includes a control panel 32, a controller
30, and
a plurality of sensors 70 that monitor the various components of the spa. For
example,
the sensors 70 may include temperature and liquid level sensors to
respectively monitor
the water temperature and water level at various locations in the spa system
10.
In the specific embodiment shown in Figure 2, the spa system 10 further
includes a
plurality of spa components in the form of a heating module 60, two water
pumps 11 &
12, a filter 26 and an air blower 24. It should be understood that the spa
system 10 could
include more or less spa components without departing from the spirit of the
invention.
For example, although not shown in Figure 2, the spa system 10 could include a
lighting
system for lighting up the water in the receptacle 18.
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In normal operation, water flows from the spa receptacle 18, through drain 22
and is
pumped by water pump 12 through heating module 60 where the water is heated.
The
heated water then leaves the heating module 60 and re-enters the spa
receptacle 18
through jets 20. In addition, water flows from the spa receptacle 18, through
drain 22 and
is pumped by water pump 11 through filter 26. The filtered water then re-
enters the spa
receptacle 18 through jets 20. Water can flow through these two cycles
continuously
while the spa system 10 is in operation. The air blower 24 is operative for
delivering air
bubbles to the spa receptacle 18.
The control system is operative for controlling the various components of the
spa system
10. The control panel 32 of the control system is typically in the form of a
user interface
that allows a user to enter commands for controlling the various operational
settings of
the spa. Some non-limiting examples of operational settings of the spa include
temperature control settings, jet control settings, and lighting settings. In
a non-limiting
embodiment where the spa is connected to entertainment and/or multimedia
modules, the
operational settings of the spa may also include audio settings and video
settings,
amongst others. Consequently, the expression "operational settings", for the
purpose of
the present invention, is intended to cover operational settings for any
suitable equipment
that can be used by a spa bather.
The control system receives electrical power from an electric power source 29
that is
connected to the controller 30. The controller 30 is then able to control the
distribution
of power supplied to the various spa components on the basis of control
signals received
from the various sensors 70 and the control panel 32 in order to cause the
desired
operational settings to be implemented.
The power source 29 supplies the controller 30 with any suitable power service
suitable
for residential or commercial use, via service wiring 31. In a non-limiting
implementation, the power source 29 can supply 240 volts (V) rms to the
controller 30
via service wiring 31. In an alternative non-limiting implementation, the
power source
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29 can supply 120 volts (V) rms to the controller 30 via service wiring 31. It
is to be
appreciated that other voltage supply values, for example depending on
geographical
location, are possible without detracting from the spirit of the invention.
5 A specific example of implementation of the controller 30 will now be
described with
reference to figures 3a, 3b, 3c and 3d.
As shown, the controller 30 for use in controlling bathing unit components in
a bathing
unit system comprises a controller body having a back surface 301 (shown in
figure 3c)
10 and a front surface 300 generally opposed to the back surface 301.
The controller body may be comprised of any suitable material including but
not limited
to cast aluminum, magnesium, sheet metal (cold roll) and molded plastic.
The front surface 300 includes a plurality of connector interfaces 34A-341 and
302A-
302F, each connector interface being adapted for receiving a corresponding
connector
associated to a respective bathing unit component (not shown), to a sensor or
to the
controller interface. The controller 30 also includes a printed circuit board
(not shown)
positioned within the controller body and on which is mounted a control
circuit. In use,
the control circuit selectively provides electrical power to respective
bathing unit
components connected through the plurality of connector interfaces 34A-341 and
302A-
302F.
Advantageously, by having the connector interfaces 34A-341 and 302A-302F
appearing
on the front surface 300 of the controller body, rather than on the periphery
thereof, a
greater ease in making the connection with the bathing unit component
connectors is
provided to the spa technician.
In addition, by having the connector interfaces 34A-341 and 302A-302F
appearing on the
front surface of the controller 30, more surface area is available for the
layout of the
connector interfaces. This allows space to provide additional connector
interfaces if
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required.
In a specific implementation, as shown in figure 3b, the controller 30
comprises a set of
fastener receiving members 362a-362d and 364a-364b adapted for receiving
fasteners for
coupling the controller 30 to a desired surface. As depicted, fastener-
receiving members
362a-362d are positioned around the periphery of the controller body and, when
used
with suitable fasteners, allow the controller to be secured to a surface
opposed to the back
surface of the controller body, such as a wall for example. Fastener-receiving
members
364a-364b are positioned around the periphery of the controller body in the
bottom
portion of the controller body and, when used with suitable fasteners, allow
the controller
to be secured to a surface below the controller body. In yet another
implementation, not
shown in the figures, fastener-receiving members are positioned around the
periphery of
the controller body in the top portion of the controller body and, when used
with suitable
fasteners, allow the controller to be secured to a surface above the
controller body. In
a specific non-limiting example of implementation, the controller 30 is
adapted to be
positioned under the skirt of the bathing unit.
Each one of the connector interfaces 34A-341 and 302A-302F, comprises a
plurality of
contact elements. In a specific implementation, the contact elements are
electrically
connected to electrical circuitry, such as a printed-circuit board or other
suitable control
circuit element, that is mounted in the controller 30 and that is adapted to
convert the
power received from the electric power source 29 into a particular voltage
and/or current
applied to each one of the contact elements.
In the specific example of implementation shown in Figures 3a, 3b and 3d the
controller
comprises a plurality of connectors 34A-341 which are adapted for providing
electrical
power to respective spa components and electrical circuitry (not shown in the
figure)
adapted for controlling the supply of power to the plurality of connectors 34A-
341. In a
specific implementation, the spa components include, for example, pumps, a
heating
30 module, an air blower, an audio system, and a lighting system. Although
Figures 3 a, 3b,
3d. show the controller 30 as including nine connectors 34A-341 for supplying
electrical
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power to nine spa components, it should be understood that the controller 30
could
include any suitable number of connectors 34 for providing electrical power to
desired
number of spa components without detracting from the spirit of the invention.
Connector
interfaces 302A-302F are optional low voltage connections, which may be used
for
various peripheral components such as control panels, light outputs, external
1/0 controls
and infrared receiver input amongst others.
The connector interfaces 34A-341 and 302A-302F include contact elements which
are
electrically connected to a printed circuit board (not shown) positioned
between the front
surface and the back surface of the controller body. The printed circuit board
receives
power via service wiring 31 from a conventional electric power source 29. The
printed
circuit board includes a variety of electrical components and patterns of
printed wiring
conductor traces that interconnect the variety of electrical components and
the service
wiring 31. Each one of the contact elements of the connector interfaces 34A-
341 and
302A-302F may be directly connected to a respective one of the printed
conductor traces,
for example, by a soldered connection, or any other suitable method known in
the art.
Alternatively, each contact element may be connected to a respective one of
the printed
conductor traces of the printed circuit board via a respective conductor wire
extending
from the contact element to the printed conductor trace. The printed circuit
board is
designed to either directly route, or convert and route directly or through a
relay, the
power received from service wiring 31 such as to achieve the particular
voltage or current
expected to be made available at each contact element of the connector
interfaces 34A-
341 and 302A-302F. In a specific non-limiting implementation, the service
wiring 31
includes a first line "line 1 ", a second line "line 2", a Neutral and earth
ground conductor
connected to 120/240 V single phase supply system. Figure 6 of the drawings
shows a
portion of a printed circuit board 600 to which is directly coupled a
connector interface
602 in accordance with a non-limiting example of implementation of the
invention. The
connector interface is adapted for receiving therein connector 604.
The printed circuit board includes a control circuit element connected to the
variety of
electrical components on the board and adapted to receive signals from various
input
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devices of the spa system 10, such as the spa control panel 32 and various spa
sensors 70
(shown in Figure 2). The control circuit element is adapted to control the
operation of the
various electrical components of the printed circuit board on the basis of the
signals
received from the various input devices such as to enable or disable the
particular voltage
or current expected to be available at any one of the connector interfaces 34A-
341 and
302A-302F. For example, in a typical interaction, a user of the spa enters
commands via
the spa control panel 32 in order to activate a particular spa component. The
control
circuit element, upon receiving signals generated by the control panel 32 on
the basis of
the entered commands, controls the various electrical components of the
printed circuit
board such as to enable the connector interfaces 34A-34I and 302A-302F
associated with
the particular spa component. Similarly, if a water level sensor was to
generate a signal
upon detecting an unacceptable water level in a particular spa component such
as the
pump 12 or the heating module 60 (shown in Figure 2), the control circuit
element, upon
receiving the generated signal, could control the various electrical
components of the
printed circuit board such as to disable the voltage and/or current available
at the contact
elements of the connector interface associated with the pump 12 or the heating
module
60.
With reference to figures 3a, 3b and 3d, in a non-limiting example of
implementation, the
controller 30 further includes an error diagnostic window 304. The error
diagnostic
window 304 provides a visual display of errors associated with the controller
30 and
generated by diagnostic functionality implemented by the control circuit. As
depicted,
the error diagnostic window 304 includes a display area and scrolling keys
allowing users
to visualize a set of errors. In a non-limiting example of implementation, the
visual
display of errors is done in the form of error codes where each type of error
is associated
to a respective error code. For example, a defective heater element may be
associated to
error code "H I" and a defective pump may be associated to an error code "P 1
". Any
suitable method for detected errors in the spa system and conveying that
information to
the spa user may be used here. The specific manner in which the errors are
detected and
generated is beyond the scope of the present application and as such will not
be described
further here. For addition information on error detection in a spa, the reader
is invited
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to refer to US patent application 10/768,130 filed on February 2, 2004 and
assigned to
the same assignee as the present application.
In a specific example of implementation, the controller 30 further includes a
set of
instructions 356 positioned on the front surface 300 of the controller body.
The
instructions may be printed on an adhesive substrate and affixed to the
controller or may
be printed or embossed directly on the controller body. The set of
instructions 356
provides guidance as to how to couple the plurality of connector interfaces
34A-341 and
302A-302F to respective connectors associated to bathing unit components.
Optionally
the set of instructions 356 may also include information regarding the
current/voltage
available at each connector interface 34A-341 and 302A-302F.
Optionally still, the set of instructions 356 also includes information on the
error codes
displayed in the error diagnostic window 304 and provide an indication of what
to do
when various codes are displayed.
Advantageously, the set of instructions 356 regarding which connectors should
be
connected to which spa components reduces the likelihood of errors from
plugging in spa
components into incorrect connector interfaces. Consequently, a technician of
low
experience with spa controllers would still be likely to correctly connect the
spa
components to the controller by following the set of instructions 356
appearing on the
front surface 300 of the controller body. In particular, by positioning the
set instructions
356 in proximity to the controller interfaces, instead of in a user manual for
example, it
is more likely that the technician will follow those instructions.
In accordance with a specific implementation, at least some connector
interfaces 34A-341
and 302A-302F include descriptive indicia providing guidance in locating
corresponding
connectors associated to bathing unit components. Such descriptive indicia may
be used
instead of the set of instructions 356 or concurrently therewith.
In a first specific example, the descriptive indicia include alpha-numeric
characters
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providing an indication of the type of bathing unit components to be coupled
to given
connector interfaces. The controller 30 depicted in figures 3a, 3b and 3d
includes
connector interfaces 34A-341 having descriptive indicia with alpha-numeric
characters.
For example:
5 - Connector interfaces 34a and 34h have descriptive indicia "AUX1" and
"AUX2"
indicating that the connector interfaces are for connection to auxiliary
modules.
Such auxiliary modules may include, without being limited to, video equipment,
computer, cooling system, external lighting system, waterfall and external
fan.
- Connector interface 34b has descriptive indicia "CP" indicating that the
10 connector interface is for connection to a circulation pump module.
- Connector interface 34c has descriptive indicia "02" indicating that the
connector
interface is for connection to an ozonator module.
- Connector interfaces 34d, 34e, 34f have descriptive indicia "PUMPS", "PUMP2"
and "PUMP 1" respectively indicating that the connector interfaces are for
15 connection to pump modules.
- Connector interface 34g has descriptive indicia "HEATER" indicating that the
connector interface is for connection to a heating module.
- Connector interface 34i has descriptive indicia "AUDIO" indicating that the
connector interface is for connection to an audio module.
In a second specific example, the descriptive indicia include color indicia
providing an
indication of the type of bathing unit component to be coupled to given
connector
interfaces. The controller 30 depicted in figures 3a, 3b and 3d includes
connector
interfaces 34A-341 and 302A-302F having descriptive color indicia. The color
indicia
allow effecting connections between the plurality of connector interfaces and
the
connectors associated to bathing unit components on the basis of a color code.
An
advantage of using a color code to effect connections is that even a
technician of no
experience and poor reading skills can easily make the connections.
Furthermore, on the
basis of a color code connection errors can be very easily detected and
corrected even by
a technician of little or no experience.
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In a third specific example, the controller 30 uses color indicia and alpha-
numeric
characters in combination to provide an indication of the bathing unit
component to be
coupled to given connector interface. The controller 30 depicted in figures
3a, 3b and 3d
includes connector interfaces 34D-34E and 34F having descriptive color indicia
and
alpha-numeric characters. The color indicia cannot be seen in the figures
since they are
in black and white however for the purpose of this example, connector
interfaces 34E and
34F are yellow and connector interface 34D is red. In this particular example:
- The alpha-numeric characters "PUMPS", "PUMP2" and "PUMP I" indicate that the
connector interfaces are for connection to pump modules.
- The yellow color indicia for connector interfaces 34E and 34F indicate that
the
connectors are rated for pumps up to 20 Amps.
- The red color indicia for connector interface 34D indicate that the
connector interface
is rated for a pump up to 15 Amps.
It will be appreciated that other suitable schemes for combining descriptive
indicia to
convey information, which will become apparent to the person skilled in the
art in light
of the present specification, may be used without detracting from the spirit
of the
invention.
Each one of the connector interfaces 34A-341 and 302A-302F, comprises a
plurality of
contact elements. In a specific implementation, the contact elements are
electrically
connected to electrical circuitry, such as a printed-circuit board or other
suitable control
circuit element, that is mounted in the controller 30 and that is adapted to
convert the
power received from the electric power source 29 into a particular voltage
and/or current
applied to each one of the contact elements.
The contact elements of the connector interfaces 34A-341 and 302A-302F are
adapted to
be electrically connected to a printed circuit board (not shown) positioned
between the
front surface and the back surface of the controller body. The printed circuit
board
receives power via service wiring 31 from a conventional electric power source
29. The
printed circuit board includes a variety of electrical components and patterns
of printed
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wiring conductor traces that interconnect the variety of electrical components
and the
service wiring 31. Each one of the contact elements of the connector
interfaces 34A-341
and 302A-302F may be directly connected to a respective one of the printed
conductor
traces, for example, by a soldered connection, or any other suitable method
known in the
art. Alternatively, each contact element may be connected to a respective one
of the
printed conductor traces of the printed circuit board via a respective
conductor wire
extending from the contact element to the printed conductor trace. The printed
circuit
board is designed to either directly route, or convert and route directly or
through a relay,
the power received from service wiring 31 such as to achieve the particular
voltage or
current expected to be made available at each contact element of the connector
interfaces
34A-341 and 302A-302F. In a specific non-limiting implementation, the service
wiring
31 includes a first line "line V, a second line "line 2", a Neutral and earth
ground
conductor connected to 120/240 V single phase supply system.
The printed circuit board includes a control circuit element connected to the
variety of
electrical components on the board and adapted to receive signals from various
input
devices of the spa system 10, such as the spa control panel 32 and various spa
sensors 70
(shown in Figure 2). The control circuit element is adapted to control the
operation of the
various electrical components of the printed circuit board on the basis of the
signals
received from the various input devices such as to enable or disable the
particular voltage
or current expected to be available at any one of the connector interfaces 34A-
341 and
302A-302F. For example, in a typical interaction, a user of the spa enters
commands via
the spa control panel 32 in order to activate a particular spa component. The
control
circuit element, upon receiving signals generated by the control panel 32 on
the basis of
the entered commands, controls the various electrical components of the
printed circuit
board such as to enable the connector interfaces 34A-341 and 302A-302F
associated with
the particular spa component. Similarly, if a water level sensor was to
generate a signal
upon detecting an unacceptable water level in a particular spa component such
as the
pump 12 or the heating module 60 (shown in Figure 2), the control circuit
element, upon
receiving the generated signal, could control the various electrical
components of the
printed circuit board such as to disable the voltage and/or current available
at the contact
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elements of the connector interface associated with the pump 12 or the heating
module
60.
In a specific example of implementation, as shown in figure 3d, the back
surface and the
front surface of the controller body are connected such as to form a first
portion 380 and
a second portion 382. The second portion 382 may be accessed independently
from the
first portion 380.
In a non-limiting implementation, a power connection interface 350 and a fuse
connector
interface 352 are positioned within the second portion 382. The power
connection
interface 350 includes a plurality of connectors adapted for receiving
electric wires
therein from service wiring 31. The control circuit mounted on the circuit
board is
positioned at least in part within the first portion 380.
Advantageously, by positioning the power connection interface 350 and a fuse
connector
interface 352 in the second portion and allowing the second portion 382 to be
accessed
independently from the first portion 380, a technician may effect the
electrical service
wiring and the fuses may be replaced in the second portion without accessing
to the
circuit board in the first portion. As such, the likelihood of damaging the
control circuit
positioned within the first portion 380 during servicing by a technician is
reduced.
In conventional controllers, there is typically a significant amount of wiring
between the
connectors and the printed circuit board. The large amount of wire does not
permit for
the mounting of connectors on a removable front panel. Since conventional
controllers
need to have a removable front panel to access the serviceable part, such as
fuses and the
input electrical power connections, the connectors need to be mounted
elsewhere, namely
on the peripheral edges of the unit.
In the embodiment described, by eliminating the need for a removable access
panel in the
first portion of the controller body by positioning the serviceable parts
separately from
the printed circuit board, the connector interfaces can easily be mounted on
the front
surface of the controller. Access to serviceable part, such as fuses and the
input electrical
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power connections is provided in the second portion through an access panel.
Therefore,
a configuration of the type described above allows for connector interfaces to
be
positioned on the front surface of the controller body with a lower risk of
potential
damage during the servicing of the controller.
Optionally, a set of instructions 354 is provided describing how connections
to the power
connection interface 350 and the fuse connector interface 352 are to be made.
Such
instructions may also include information elements such power requirements,
fuse
type/capacity, manner in which to connect the service wiring amongst others.
The
instructions are preferably positioned in proximity to the power connection
interface 350
and a fuse connector interface 352 such as to facilitate reference thereto by
the technician.
As such, the likelihood of effecting an incorrect connection is reduced. In
the
embodiments illustrated in figure 3b, a set of instructions 354 is positioned
next to the
power connection interface 350 and the fuse connector interface 352 as shown
in figure
3b or may be positioned on the inside surface of the access panel 360. The
instructions
may be printed on an adhesive substrate and affixed to the controller or may
be printed
or embossed directly on the controller body.
In a non-limiting example of implementation, the power connection interface
350
includes a plurality of connectors 552 generally aligned along a first axis
550 as shown
in figure 5. Each connector 552 is associated to a respective connection path
554 through
which respective wires 502 pass in order to effect electrical connections. In
the non-
limiting example of implementation shown in figure 5, the connection paths 554
are
positioned at an angle from a second axis 560, where the second axis 560 is
generally
perpendicular to the first axis 550. Advantageously, positioning the plurality
of
connection paths 554 at an angle from the second axis 560, rather than
substantially
aligned therewith, allows for greater ease in effecting the electrical
connections through
wires 502.
More specifically, in the configuration depicted in figure 5, positioning the
plurality of
connection paths 554 at an angle from the second axis 560 allows electrical
wires to be
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bent only once from the entrance of the electrical wires in the controller
body to the
connectors 552. The increased play generated by the single bend, will
facilitate the
manipulation of a large wire gage and ease the connection process. In systems
where the
connection paths are aligned with axis 560, at least two bends of the
electrical wire are
5 required in order to make some adjustment to reach the connector through the
connection
paths unless each wire included in the input cable is of the precisely exact
length, witch
is difficult to achieve with large multiple wire gage.
It will be appreciated that the angle between the connection paths 554 and the
second axis
10 560 may vary depending on implementations and that such alternative
implementations
fall within the scope of the present application. In specific implementations,
angles
between about 25 and about 75 from the second axis 560 have been found to
yield
improved ease of connection. It will also be appreciated that the angle
between the
connection paths 554 and the second axis 560 may vary from one connection path
to
15 another and that such alternative implementations fall within the scope of
the present
application.
The second portion 382 includes an access panel 360 providing access to the
inside of the
second portion 382. In a specific example of implementation, the access panel
360 is
20 moveable between a closed position and an open position. Various
configurations are
possible for the access panel 360. In a first example, the access panel is
moveable
between a closed position, as shown in figure 3a, and an open position, as
shown in figure
3b, through a hinge member 358. In a second example (not shown in the
figures), the
access panel is releasably fastened to the controller body by a set fasteners.
Any suitable
fasteners may be used here without detracting from the spirit of the
invention. In a third
example, as shown in figures 3a and 3b, the access panel is releasably
fastened to the
controller body by a set fasteners 310 in addition to a hinge member 358
through which
the access panel is moveable between a closed position and an open position.
In yet
another example, the access panel is adapted to slidingly engage a guiding
path in the
controller body in order to move the panel between a closed position and an
open
position. It will be readily apparent to the person skilled in the art that
other suitable
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configurations for the access panel are possible. Optionally, the second
portion 382 includes a
sealing member (such as a gasket or other means) to prevent water from
entering the inside of the
second portion 382 under normal controller 30 use. The sealing member is
usually position about
the periphery of the access panel 360. It will be appreciated that in certain
alternative
implementations, the access panel 360 may be totally absent and that in such
implementations the
electrical connectors 350 and the fuses 352 are exposed.
In a specific implementation, the first portion 380 is sealed such as to
prevent access thereto by a
technician. The first portion contains at least part of the circuit board,
which is in communication
with the power connection interface 350 and with the plurality of connector
interfaces, and on
which is mounted the control circuit.
The control circuit is mounted on a circuit board in communication with the
power connection
interface 350 and with the plurality of connector interfaces. The circuit
board is positioned at
least in part within the first portion 380.
In a specific example of implementation, the first portion is sealed such as
to reduce the
likelihood of water entering the first portion. The seal may create a water
resistant or waterproof
enclosure such that the control circuit positioned within the first portion is
not put into contact
with water. This is particularly advantageous since the controller 30 is used
in the context of a
spa system or other bathing system.
The first portion 380 may be permanently sealed or releasably sealed. In a
first specific
implementation, the first portion 3 80 is sealed by providing a key-type latch
that provides access
to the first portion to the holder of the appropriate key. In a second
specific implementation, the
first portion is sealed with an epoxy adhesive or a gasket material along at
least part of its
periphery. In a third specific implementation, the first portion is sealed
with a set of fasteners such
as screws, bolts and nuts, or any other suitable type of mechanical fastener.
It will be readily
apparent to the person skilled in the art that other suitable methods for
sealing the first portion 380
may be used here.
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As shown in the figures, the plurality of connector interfaces 34A-341 and
302A-302F are
positioned on the first portion 380.
Those skilled in the art will appreciate that various modifications and
refinements can be made to
the embodiments presented above without detracting from the scope of the
present invention.
It is to be understood that the functionality of the control circuit element
could be implemented by
any suitable hardware and/or hardware/software combination without departing
from the spirit
and scope of the present invention. In a non-limiting example, the control
circuit element is in the
form of a microprocessor. In addition, it will also be appreciated that the
control circuit element
could be implemented by other suitable circuitry, including, by way of example
only, an
application-specific integrated circuit (ASIC), or discrete logic circuitry.
Other variations, modifications and refinements to the above embodiments
described are possible.
