Note: Descriptions are shown in the official language in which they were submitted.
TEST AND MONITORING SYSTEM FOR A DUAL SUMP PUMP INSTALLATION
BACKGROUND OF THE DISCLOSURE
[0001] The present disclosure relates to an automated system for monitoring
and
testing sump pump installations of the type commonly used in residential and
commercial
building basements. In particular, the disclosure is directed to a monitoring
system for a
sump pump installation which regularly tests and monitors the installation and
proactively
provides confirmation of a successful test and an alarm in the event of an
unsuccessful
test, and to improvements therein.
[0002] More specifically, sump pump installations are frequently provided
in
residential and commercial basements to remove ground water that accumulates
around
foundation footings and under the basement floor. To this end, a network of
apertured
drain tiles or flexible drain hoses is laid adjacent to the footings of the
foundation walls on
either the interior side or the exterior side of the walls, or both. These
drain tiles or hoses
are appropriately routed and sloped to drain accumulated water into one or
more sump
liners, which typically have inlets connecting with the network of drain
tiles/hoses and are
set in the basement floor to form a sump pit having a bottom portion below
that of the
tiles/hoses. The most commonly used type of sump pumps are electrically-
powered sump
pumps designed to be at least partially submerged by water in the sump pit. At
least one
electrically-powered sump pump is typically positioned in the sump pit and,
when
powered, functions to discharge water from the pit through a discharge pipe to
a dispersal
location, such as a storm sewer or exterior dispersal field. The sump pump
typically
includes a float switch which causes it to operate when the level of ground
water (or other
liquid) in the sump pit has reached a predetermined trigger level, ordinarily
set below the
lowest inlet in the liner wall. That float switch also typically terminates
operation of the
pump when the water reaches a predetermined minimum level below the trigger
level. A
check valve prevents water remaining in the discharge pipe from flowing back
into the
sump pit.
[0003] Should the sump pump fail to operate for any reason, such as, for
example,
motor failure, pump failure, or power failure, and should the drain network
continue to
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flow ground water into the sump pit, the pit will often eventually overflow
from the top of
the sump liner and flood into the basement. This flooding may result in
significant and
often costly damage to items stored in the basement, as well as to existing
basement
improvements such as finished walls and furniture.
[0004] Various monitoring systems have come into use for warning the home
or
business owner of an impending overflow of the sump pit. Typically, these rely
on a float
switch or other types of liquid level detectors to sense an abnormally high
liquid level in
the sump pit and to cause an alarm to be sounded and/or a warning message to
be sent to
the owner. The drawback of these systems is that they only function when the
pump is
already in a condition in which it is no longer capable of preventing
flooding, i.e. when
the pump has failed and the pit is about to overflow. This is frequently too
late for
corrective action to be taken.
[0005] Another type of monitoring system that has come into use provides an
independent liquid level sensing float switch, or other equivalent liquid
level sensing
device, in the pit which functions to supply power to the pump when a
predetermined
trigger level is reached. The current drawn by the motor and a fall in the
liquid level in the
pump is then utilized to confirm operation of the pump. Unfortunately, an
alarm is only
sounded at a time when operation of the pump is required to prevent flooding
but the
pump does not operate. This, again, may be too late for any corrective action
to be taken.
[0006] Still other monitoring systems purport to reduce the likelihood of
an overflow
by providing a second back-up pump, typically set at a slightly higher level
in the pit so as
to operate only upon failure of the first pump, or an AC backup power source
for the
primary pump, such as a standby generator or a battery-powered inverter. Other
systems
provide a secondary DC battery-driven pump in the sump pit alongside the
primary AC-
driven pump. Another monitoring system, in addition to providing two pumps in
the sump
pit, causes the pumps to alternate in operation in response to incoming ground
water
thereby equalizing use between the pumps. While the provision of these systems
may
reduce the likelihood of a system failure, they do not proactively identify a
pump failure
prior to an impending flood event requiring immediately operation of the pump.
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[0007] In contrast, the test and monitoring system of the present
disclosure along with
the described improvements therefor periodically confirms the operability of a
sump pump
installation and alerts the owner of a malfunction prior to the sump
installation being
required to operate to discharge drain water. This protective testing gives
the owner
sufficient time to correct the malfunction and thereby avoid what might
otherwise be a
serious basement flooding event. In the event the test and monitoring system
of the
disclosure is utilized in a two pump installation, both pumps are
independently tested and
monitored, and a failure of either pump, or both pumps, results in an alarm
being sounded
and appropriate messages being sent to the owner and/or the owners'
designee(s) by
communications channels such as, for example, the Internet, cell phone data or
land line
telephone communication channels.
[0008] Moreover, the regular and automatic testing provided by the test and
monitoring
system of the present disclosure has the further benefit of periodically
placing any sump
pumps in the monitored system in full operation to actually discharge water
from the sump
pit, thereby helping to prevent seals and bearings in the pump(s) and their
motor(s) and
associated cheek valve(s) from drying out or binding. Prior monitoring systems
are
reactive in that they act only in the event the monitored sump installation is
actually called
on to evacuate rising ground water, which may be only after extended periods
of non-
operation.
[0009] Accordingly, it is a general object of the present disclosure to
provide an
improved automatic test and monitoring system for a sump pump installation.
[0010] It is a more specific object of the present disclosure to provide an
automatic
sump pump test and monitoring system which functions proactively to alert a
user to a
malfunctioning sump pump installation prior to the installation being required
to prevent
an impending overflow and flood condition.
[0011] It is a still more specific object of the present disclosure to
provide a sump
pump test and monitoring system which periodically tests the operation of a
sump pump
installation and provides an alarm to the user in the event the installation
fails to perform
satisfactorily.
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[0012] It is yet another specific object of the disclosure to provide a
sump pump test
and monitoring system which regularly admits liquid to the sump pump container
of a
sump pump installation to force the sump pump of the installation through a
test cycle
whereby satisfactory operation can be verified in advance of any actual need
for the pump
installation.
[0013[ It is yet another specific object of the present disclosure to
provide an improved
automatic test and monitoring system in accord with the above stated objects
which is
functional with either or both AC-powered and battery-powered DC sump pumps.
[0014] It is yet another specific object of the present disclosure to
provide in an
improved sump pump test and monitoring system a removable current sensing
module for
installation on a conductor supplying direct current to a DC motor to enable
the testing
and monitoring of a battery-powered sump pump without regard to the duration
of current
flow.
[0015] It is yet another specific object of the present disclosure to
provide a sump
pump test and monitoring system which incorporates improvements in sensing,
control
and activation circuitry and systems therein to provide improved performance
and
reliability.
[0016] It is yet another specific object of the present disclosure to
provide in an
improved sump pump test and monitoring system an electrically actuated valve
module
having an independently connected flow transducer which provides a fault
signal in the
event of the valve failing in either a closed or in an open condition.
[0017] It is yet another specific object of the present disclosure to
provide in an
improved sump pump test and monitoring system a liquid level sensing module
having
dual independently connected float switches wherein the failure of either
float switch
results in a fault signal, and the remaining float switch provides a liquid
level alarm
signal.
[0018] It is yet another specific object of the present disclosure to
provide in an
improved sump pump test and monitoring system a time out adjustment circuit
for causing
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the time out of a sump pump test cycle in response to variations in the flow
rate of fresh
water into the sump container.
[0019] It is yet another specific object of the present disclosure to
provide in an
improved sump pump test and monitoring system a circuit for recording and
tracking
trends and deviations in the run time and current consumption of a monitored
sump pump
to provide a warning signal in advance of a malfunction.
[0020] It is yet another specific object of the present disclosure to
provide in an
improved sump pump test and monitoring system a circuit enabling initiation of
a sump
pump test cycle in one or more designated installations from a remote location
manually
or automatically in advance of a weather event having a potential for
flooding.
[0021] It is yet another specific object of the present disclosure to
provide in an
improved sump pump test and monitoring system a valve safety circuit providing
protection against unintended actuation of the fill valve module as a result
of a failure of
the microprocessor by requiring the microprocessor to independently generate a
unique
command signal which is recognized by the safety circuit prior to activating
the valve
module.
BRIEF SUMMARY OF THE DISCLOSURE
[0022] In accordance with the disclosure, an automated system for testing
and
monitoring a sump pump installation of the type having a liquid container, and
a first
electrically-driven sump pump which, when actuated by a rising liquid level in
the
container, pumps liquid from the container, and a second electrically driven
sump pump
which, when actuated by rising liquid level in the container, pumps liquid
from the
container; comprises a liquid conduit including an electrically-actuated valve
which in
response to an applied actuation signal, admits fresh water into the
container; and a test
control module having a first test cycle which inhibits operation of the
second pump and
applies an actuating signal to the valve to admit fresh water into the
container until the
first pump, if functional, pumps liquid from the container, and a second test
cycle which
inhibits operation of the first pump and applies an actuating signal to the
valve to admit
CA 2931191 2017-10-18
fresh water into the container until the second pump, if functional, pumps
liquid from the
container; the test control module including first and second indicator
circuits which
indicate for each pump following completion of the first and second test
cycles whether
the test cycles were successful or unsuccessful, respectively.
BRIEF DESCRIPTION OF TIIE DRAWINGS
[0023] The present disclosure will be more fully understood by reference to
the
following detailed description of one or more preferred embodiments when read
in
conjunction with the accompanying drawings, in which like referenced
characters refer to
like elements throughout the drawings, and in which:
[0024] FIG. 1 is a simplified cross-sectional view partially in
perspective of a
conventional single sump pump installation having a liquid container, a motor-
driven
pump, a float switch integral to the pump, a pump discharge pipe and a high
liquid level
alarm.
[0025] FIG. 2 is a simplified cross-sectional view partially in
perspective of a
single sump pump installation which incorporates an automated test and
monitoring
system constructed in accordance with the present disclosure.
[0026] FIG. 3 is an enlarged perspective view of the solenoid-actuated
liquid valve
assembly utilized in the test and monitoring system of FIG. 2.
[0027] FIG. 4 is an enlarged cross-sectional view partially in perspective
of the
solenoid-actuated valve assembly of FIG. 3.
[0028] FIG. 5 is an enlarged perspective view in cross section showing the
float
switch assembly utilized in the test and monitoring system of FIG. 2.
[0029] FIG. 6 is an enlarged cross-sectional view partially in perspective
of the
float switch utilized in the float switch assembly of FIG. 5.
[0030] FIG. 7 is an enlarged perspective view of the control module of the
sump
pump test and monitoring system of FIG. 2 adapted for mounting on a wall or
other flat
support surface.
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[0031] FIG. 8 is an enlarged perspective view in an alternate housing
construction
for the control module of FIG. 7 adapted for mounting directly on the
discharge pipe of
the sump pump installation.
[0032] FIG. 9 is a simplified functional block diagram partially in
schematic form
showing the principal components of the test and monitoring system of FIG. 2.
[0033] FIG. 10 is a simplified functional block diagram partially in
schematic form
showing the implementation of the test and monitoring system of FIG. 9
utilizing a
microprocessor.
[0034] FIG. 11 is a cross-sectional view partially in perspective showing
an
automated test and monitoring system constructed in accordance with the
disclosure in use
with a dual pump sump pump installation.
[0035] FIG. 12 is an enlarged perspective view of the control module
utilized in the
sump pump test and monitoring system of FIG. 11.
[0036] FIGS. 13A and 13B comprise a simplified functional block diagram
partially
in schematic form showing the principal components of the test and monitoring
system of
FIG. 11.
[0037] FIG. 14 is a simplified functional block diagram partially in
schematic form
showing the implementation of the sump pump test and monitoring system of FIG.
13
utilizing a microprocessor.
[0038] FIG. 15 is a simplified cross-sectional view partially in
perspective of a
sump pump test and monitoring system constructed in accordance with the
present
disclosure and having a liquid container, a single battery-powered sump pump,
an
improved electrically-actuated valve assembly, an improved float switch
assembly and a
current probe assembly for rising current supplied to the pump motor.
[0039] FIG. 16 is an enlarged perspective view of the improved
electrically-
actuated valve assembly of FIG. 15 showing the solenoid-actuated valve and
flow sensor
utilized therein.
[0040] FIG. 17 is a side elevational view partially in cross-section of
the valve
assembly of FIG. 16.
[0041] FIG. 18 is a side elevational view partially in cross-section of
the improved
float switch assembly of FIG. 15 showing the independently sensed dual float
switches
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utilized therein.
[0042] FIG. 19 is an enlarged cross-sectional view of the dual float
switches and
common switch housing utilized in the float switch assembly of FIG. 18.
[0043] FIG. 20 is an enlarged perspective view of the control module of
the sump
pump test and monitoring system of FIG. 15 adapted for mounting on a wall or
other flat
surface.
[0044] FIG. 21 is an enlarged perspective view of an alternate
construction for the
control module of FIG. 20 adapted for mounting directly on the discharge pipe
of the
sump pump installation.
[0045] FIG. 22 is a simplified functional block diagram partially in
schematic form
showing the principal components of the test and monitoring system of FIG. 15.
[0046] FIG. 23 is a simplified functional block diagram partially in
schematic form
showing the implementation of the test and monitoring system of FIG. 15
utilizing a
microprocessor.
[0047] FIG. 24 is a simplified cross-sectional view partially in
perspective of a
sump pump test and monitoring system constructed in accordance with the
present
disclosure and similar to the system of FIG. 15 except utilizing an AC-powered
pump and
a battery-powered pump.
[0048] FIG. 25 is an enlarged perspective view of the control module of
the sump
pump test and monitoring system of FIG. 24.
[0049] FIGS. 26A and 26B comprise a simplified block diagram partially in
schematic form showing the principal components of the sump pump test and
monitoring
system of FIG. 24.
[0050] FIG. 27 is a simplified functional block diagram partially in
schematic form
showing the implementation of the test and monitoring system of FIGS. 26A and
26B
utilizing a microprocessor.
[0051] FIG. 28 is a simplified block logic diagram illustrating the
circuitry
associated with the liquid level sensing module shown in FIGS. 18 and 19.
[0052] FIG. 29 is a simplified block diagram partially in schematic form
of the
current probe module shown in FIGS. 15 and 24.
[0053] FIG. 30 is an enlarged perspective view of the housing of the
current probe
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module shown in FIGS. 15, 24 and 29.
[0054] FIG. 31 is a simplified functional block diagram illustrating a
system
optionally incorporated in the sump pump test and monitoring systems of the
disclosure
for automatically adjusting the time out period of the pump test cycles in
accordance with
the actual flow rate of fresh water entering the sump container through the
electrically-
actuated valve module.
[0055] FIG. 32 is a simplified block diagram illustrating a system
optionally
incorporated in the sump pump test and monitoring systems of the disclosure
for detecting
and reporting trends and deviations in AC and battery-powered sump pump
performance.
[0056] FIG. 33 is a simplified block diagram illustrating a system
optionally
incorporated in the sump pump test and monitoring systems of the disclosure
for initiating
a test cycle for one or more designated systems from a remote location by
means of the bi-
directional communications channel in such systems to facilitate selective
testing in the
event of imminent events, such as an approaching storm.
[0057] FIG. 34 is a functional block diagram partially in schematic form
of a fail
safe valve driver circuit optionally incorporated in the sump pump test and
monitoring
systems described in the present disclosure.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0058] The following description of the preferred embodiments is merely
exemplary in
nature and is no way intended to limit the disclosure, its application or use.
[0059] Referring to FIG. 1, a prior art sump pump installation 10 of the
type commonly
used in basements of homes or businesses generally consists of a sump
container or liner
11 having multiple inlets 12 through which drain water is received from one or
more
perforated hose or tile systems (not shown) disposed around the foundation
footings of the
building in which the sump pump installation is located. A motor driven sump
pump 13 is
typically positioned at or near the bottom of container 11, and may be
supported by one or
more bricks 14 or other spacers located between sump pump 13 and the bottom of
container 11. Sump pump 13 may include an integral float switch assembly 15
which
forms part of an electric circuit including a power cord 16 which supplies
electric power
to the pump motor upon the water level in container 11 rising to a first
predetermined
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level Ll. This causes pump 13 to discharge water from container 11 through a
discharge
pipe 17 and a conventional check valve 18 to a storm drain or other water
dispersal
facility (not shown). Float switch assembly 15 interrupts the application of
electric power
to the pump motor when the water level in container 11 falls to a second
predetermined
level L2 below the first predetermined level Ll.
[0060] Frequently, a high water monitoring system 20 may be provided to
signal that
the water level in container 11 has risen to a third predetermined level L3
above the first
predetermined level L 1 , and therefore above the normal operating range of
pump 13 to
alert the user of a possible pump failure. In the illustrated embodiment of
FIG. 1,
monitoring system 20 includes a second float switch assembly 21 positioned
within
container 11 such that when the water level in the container rises to the
third
predetermined level L3, float switch 21 closes and provides an actuating
signal through a
cable 22 to an alarm module 23. The alarm module 23 may include an aural alarm
transducer 24 and a connector 25 for remotely signaling the high water
condition. Power
may be supplied to the high water monitor system 20 by means of a conventional
power
cord 26.
[0061] Sump pump 13 in the embodiment of FIG. 1 is connected directly to
the AC line
by cable 16, the integral float switch assembly 15 serving to control the
application of AC
power to the pump motor. In other embodiments, sump pump 13 may be provided
with an
external non-integral float switch (not shown) which may be separately
connected through
another cable (not shown) to the AC power source of the pump. Typically, the
additional
cable is provided with a break-out connector (not shown) which includes an AC
plug for
insertion into an AC supply wall outlet on one side and a switched AC
receptacle on the
opposite side for receiving the AC plug on the end of the pump power cord. The
AC plug
is inserted into the AC supply receptacle and the AC plug associated with the
pump motor
is inserted into the switched AC receptacle of the break-out connector. This
has the
advantage of allowing float switch assembly 15 to be replaced without
replacing or
dismantling sump pump 13, and enables sump pump 13 to be tested by removing
the AC
plug of the pump power cord from the break-out connector and inserting the
conventional
AC plug of the pump motor directly into the AC supply wall outlet.
CA 2931191 2017-10-18
[0062] In other embodiments, an independent control circuit (not shown) is
provided
for powering the pump motor. In these installations, the pump motor has no
associated
flow switch and receives operating power from the independent control system.
The
independent system may include one or more float switches or other water level
detecting
devices which cause the pump motor to be powered and unpovvered as the water
level in
the sump container rises and falls to predetermined levels. These independent
pump
control systems may include means for monitoring the current draw of the motor
to
provide an alarm in the event of pump motor failure.
[0063] Referring to FIG. 2, a sump pump test and monitoring system 30
constructed in
accordance with one embodiment of the disclosure is provided to automatically
and
proactively test and monitor the operation of the sump pump installation and
provide an
alarm in the event of the sump pump installation failing to operate. System 30
includes a
control module 31 which contains the electronic circuitry and various
switches, indicators
and connectors associated with the system. System 30 further includes in
accordance with
the disclosure a valve assembly 32 for admitting fresh water to container 11.
Valve
assembly 32 is mounted directly on pump discharge pipe 17 and includes a
solenoid-
actuated valve 33 which is connected on one side to a fresh water supply (not
shown) by a
length of flexible tubing 34 and on its other side to container 11 by either a
length of
flexible hose or a length of semi-rigid copper tubing 35. The fresh water
source is
preferably accessed by a length of copper tubing 36 which extends from the
source and
connects to the length of flexible tubing 34 through a manual shutoff valve
37. The
solenoid of solenoid valve 33 is electrically connected to control module 31
by a cable 38.
Valve assembly 32, together with the length of flexible tubing 34 and the
length of semi-
rigid copper tubing 35 provides a fluid conduit which supplies fresh water to
container 11
when called for by test and monitoring system 30.
[0064] Test and monitoring system 30 further includes a float switch
assembly 40
positioned within container 11 at a predetermined level L3 by an adjustable
bracket 41
secured to pump discharge pipe 17. Upon the water level in container 11 rising
to level
L3, float switch assembly 40 is actuated and provides an electrical signal to
circuitry
within control module 31 through a cable 42 which signals that the water level
in
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container 11 has risen to a level above the maximum level that would be
achieved if sump
pump 13 were operative.
[0065] Control module 31 includes an AC receptacle 43 for receiving a
conventional
AC plug on the end of the power cord 16 of pump motor 13. Control Module 31
also
includes an AC power cord 44 for receiving AC power from an AC supply wall
receptacle
(not shown). In one embodiment, four connectors 45-48 (see FIGS. 2 and 7) are
provided
on the front panel of control module 31 to connect to the various components
of system
30. In particular, connector 45 connects to cable 38 of the valve assembly 33,
connector
46 connects to cable 42 of float switch assembly 40, connector 48 connects
through a
cable 49 to an (optional) external communication module 50, and connector 47
provides
dry contacts for connection to an external alarm system.
[0066] As shown in FIGS. 3 and 4, solenoid actuated valve assembly 32
includes a
base member 51 on which the solenoid-actuated valve 33 is mounted by machine
screws
39 or other appropriate means. It will be appreciated that other valve
mounting
configurations may be provided as dictated by the construction of the valve
body. Valve
33, which may be conventional in design and construction, includes a solenoid
actuator 52
and conventional inlet and outlet fittings 53 and 54 on respective sides of
the valve to
receive and engage conduits 34 and 35, respectively. A removable cover 55
dimensioned
to securely engage the rim of base member 51 is preferably provided to protect
the valve
from mechanical damage. The cover may include slots 56 and 57 to accommodate
the
tubing segments on either side of the valve. The cover may he secured in place
by a
plurality of (machine) screws 58 threaded into the top surface of base member
51. Base
member 51 is preferably provided with an appropriately shaped laterally-
extending
channel 60 (see FIG. 3) on its bottom surface to contiguously engage the outer
surface of
discharge pipe 17. Two laterally-spaced adjustable retaining straps 61 and 62
(see FIG. 4)
are provided to firmly secure base member 51 to discharge pipe 17.
[0067] Referring to FIG. 5, float switch assembly 40 includes an adjustable
bracket 41
which is secured to pump discharge pipe 17 by means of a base member 65. Base
member
65 includes a laterally-extending channel 66 on its rear surface shaped to
contiguously
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engage the outer surface of pump discharge pipe 17. An adjustable strap 67
extends from
base member 65 around discharge pipe 17 to draw the base member tightly
against the
pipe and thereby hold float switch assembly 40 firmly in position.
[0068] As shown in FIG. 6, float switch assembly 40 includes a generally
cylindrical
housing 68 forming a chamber 70. Housing 68 includes a plurality of apertures
71 through
which liquid is admitted into the chamber. A float switch assembly 72 is
provided within
chamber 70. Float switch assembly 40 further comprises a hollow shaft 73
formed of a
non-magnetic material within which at least one magnetically-actuated reed
switch 74 is
positioned. A toroid-shaped float assembly 75 containing an internal magnet is
dimensioned to slide along the axis of shaft 73 as the water level rises and
falls within the
chamber. A pair of washers 76 and 77 attached to shaft 73, limit the axial
movement of
float assembly 75 such that the magnet in float assembly 75 overlies and
actuates reed
switch 74 as it reaches its maximum level. Reed switch 74 is electrically
connected to
module 31 by cable 42 to signal the circuitry within the module that the reed
switch has
been actuated by the water level in container 11 rising to level L3. Switch
assembly 72 is
held in position along the axis of cylindrical chamber 70 by a threaded end
portion 78 of
shaft 73 secured to the upper end of the housing by appropriate mounting
hardware 79.
[0069] It will be appreciated that the liquid level sensing function of
float switch
assembly 40 can be accomplished by other forms of water level detectors. For
example, a
conventional float switch of the type having a float and an arm connected to a
mechanically actuated switch can be utilized. Or, an electronic switch either
of the type
which senses conductivity between two sensing electrodes, or of the type that
senses water
pressure on a submerged pressure transducer, can be utilized.
[0070] As shown in FIG. 7, control module 31 of test and monitoring system
30 may
include a generally rectangular housing 80 having flanges 81 and 82 for
mounting to a
wall or other flat support surface. Front panel 83 of the module may include a
three-color
LED indicator lamp 84 for visually indicating the status of the sump pump
installation
being tested and monitored. In a preferred embodiment, this indicator
illuminates green
for a functioning pump installation, red for a non-functioning pump
installation, and
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amber for a pump installation untested or under test. The amber indication may
be flashing
while the solenoid-actuated valve 33 is admitting water to container 11. A
test of the sump
pump installation can be manually initiated by means of a push-button TEST
switch 85
located on front panel 83. Momentarily pressing switch 85 initiates a normal
test cycle of
the pump sump installation. An unsatisfactory test result is signaled to the
user by
indicator 84 flashing red and an aural alarm provided by a panel-mounted
transducer 86.
The aural alarm, which is preferably in the form of a loud repetitive "beep"
or "chirp," can
be reset by momentary actuation of a push-button RESET switch 87, also located
on front
panel 83. Momentarily pressing this switch will silence the aural alarm and
change the
accompanying flashing red indication of indicator 84 to a steady red
indication for a
predetermined period of time, such as, for example, six hours, after which the
aural alarm
and flashing red indication again occur. Shorter or longer time periods for
muting the
alarm can be programmed into system 30 as desired.
[0071] Actuating RESET switch 87 for an extended period of time, such as,
for
example, five seconds, will result in a complete reset of the system. The
flashing or steady
red illumination of indicator 84 will extinguish and the aural alarm provided
by transducer
86 will cease. However, a green illumination of indicator 84 indicating a
satisfactory
pump installation test will not occur until test switch 85 has been
subsequently actuated
and a subsequent test of the installation has been satisfactory.
[0072] Various fault details, such as internal battery status, AC supply
status, sensor
status, valve status, and communications status, may be provided by a
plurality of
indicator lamps 88a-88f on front panel 83. In addition, a removable cover 89
may be
provided to access a rechargeable battery (not shown in FIG. 7) provided
within housing
80 to power the test and monitoring system circuitry within module 31 in the
event of AC
power failure.
[0073] Referring to FIG. 8, control module 31 of test and monitoring system
30 may be
contained in an alternative housing 90 adapted to be mounted directly on the
outer surface
of pump discharge pipe 17. In this embodiment, rear wall 91 of housing 90 is
provided
with a channel 92 shaped to contiguously engage the outer surface of discharge
pipe 17. A
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pair of adjustable straps (not shown) extends from the rear wall 91 and wrap
around
discharge pipe 17 to draw the housing into contiguous firm engagement with
pipe 17. The
same controls, indicators and connectors present in the embodiment of FIG. 7
can be
provided in this embodiment.
[0074] FIG. 9 illustrates the principal components of one embodiment of the
test and
monitoring system 30 of the present disclosure in a simplified functional
block diagram.
As shown therein, the occurrence of a test cycle is determined by a TEST CYCLE
LATCH
100 which transitions to a SET state during the occurrence of a test cycle,
and to a RESET
state in the absence of a test cycle. In normal use, TEST CYCLE LATCH 100 is
periodically conditioned to a SET state by an EVENT TIMER 101 which provides a
momentary output signal through an OR gate 120 on a calendar basis or after a
predetermined time interval has lapsed following the most recent input applied
to the
timer. In one embodiment, EVENT TIMER 101 may be set, for example, to generate
a
momentary output signal either every seven days, or every seven days after
receipt of the
most recent input signal, in which case a test cycle of the sump pump
installation will
occur.
[0075] When TEST CYCLE LATCH 100 is in a SET state, a signal is also
applied
through an AND gate 102 and a solenoid driver circuit 103 to solenoid 52 of
valve
assembly 33 to condition valve assembly 33 to admit water into container 11.
Water
continues to be admitted until either TEST CYCLE LATCH 100 reverts back to a
RESET
state, or the high water float switch assembly 40 provides an inhibit signal
to AND gate
102. When valve assembly 33 is open, FLASHER CIRCUIT 99 is activated to cause
the
amber illumination of indicator 84, if active, to flash.
[0076] When TEST CYCLE LATCH 100 is in a SET state, it provides an output
signal
causing indicator 84 to illuminate amber through an AND gate 104 and an LED
driver
105. Also, TEST CYCLE LATCH 100 in its SET state resets a TEST SUCCESSFUL
LATCH 106 through a signal conditioning pulse circuit 107 and an OR gate 108,
and
resets a TEST FAIL LATCH 111 through an OR gate 95. This terminates the output
of
TEST SUCCESSFUL LATCH 106 such that the green illumination of indicator 84
driven
CA 2931191 2017-10-18
through an LED driver 109 is extinguished, and the output of TEST FAIL LATCH
111
such that the red illumination of indicator 84 driven through AND gate 96 and
an LED
driver 113 is extinguished. Thus, only the amber illumination of indicator 84
is active
during a test cycle.
[0077] The output of TEST CYCLE LATCH 100 is also applied to a TEST CYCLE
TIMER 110 which times the duration of the test cycle and provides a momentary
timeout
output signal in the event the duration of the SET state of TEST CYCLE LATCH
100, and
hence the duration of the test cycle, exceeds a predetermined maximum period
of time. In
the event of this timeout, TEST CYCLE TIMER 110 applies a SET signal to
transition
TEST FAIL LATCH 111 to a SET state through an OR gate 112. This causes a red
illumination of indicator 84 through AND gate 96 and LED driver 113. Also, the
output of
TEST CYCLE TIMER 110 causes TEST CYCLE LATCH 100 to be reset by means of a
signal provided through an OR gate 114, thereby terminating the test cycle and
extinguishing the amber illumination of indicator 84. The output of TEST FAIL
LATCH
111 conditions an ALARM LATCH 115 to a SET state through an interface circuit
116,
thereby causing an AUDIO GENERATOR 97 to generate an audible alarm through
transducer 86. ALARM LATCH 115 can be reset by momentary actuation of RESET
switch 87, in the manner previously described. ALARM LATCH 115 also enables
FLASHER CIRCUIT 98 to cause the red illumination of indicator 84 to flash
until the
latch is reset. RESET switch 87 also serves, through a delay circuit 117, when
held for an
extended period of time, to reset TEST CYCLE LATCH 100 through OR gate 114, to
reset
TEST FAIL LATCH 111 through OR gate 95, and to reset TEST SUCCESSFUL LATCH
106 through OR gate 108, thereby conditioning the system for a subsequent
test. A manual
test can be initiated by TEST switch 85 through a signal conditioning pulse
circuit 119
and OR gate 120.
[0078] The output of MOTOR CURRENT SENSOR 121 also provides a reset signal
through a switch and a signal conditioning pulse circuit 122 to EVENT TIMER
101,
optimally causing that timer to begin a new timing period with each operation
of the
motor. The output of MOTOR CURRENT SENSOR 121 is also applied to a signal
conditioning pulse circuit 123, which provides a momentary pulse upon the
motor
16
CA 2931191 2017-10-18
stopping. This pulse, signaling the completion of a successful test, is
applied through OR
gate 114 to reset TEST CYCLE LATCH 100 to terminate the test cycle. The same
motor
stop pulse also serves to condition the TEST SUCCESSFUL LATCH 106 to a SET
status
to indicate successful completion of a test cycle by illuminating the green
indication of
indicator 84 through LED driver 109. A further function of MOTOR CURRENT
SENSOR
121 is to initiate a timeout period in a MOTOR RUN TIMER 124. In the event
pump
motor 13 operates continuously for a period exceeding the timeout period of
MOTOR
RUN TIMER 124, the timer generates an output signal which resets TEST CYCLE
LATCH 100 through OR gate 114 and conditions TEST FAIL LATCH 111 to a SET
state
through OR gate 112. This causes the red illumination of indicator 84 through
AND gate
93 and LED driver 113. Also, the output of MOTOR RUN TIMER 124 resets the TEST
SUCCESSFUL LATCH 106 through OR gate 108 to extinguish the green illumination
of
indicator 84.
[0079] In the event pump motor 13 fails to operate during a test cycle, the
eventual
closure of high water sensing switch assembly 40 causes an inhibit signal to
be applied to
AND gate 102, preventing further operation of solenoid 52 to prevent further
water from
being admitted to sump container 11. Also, the closure of high water level
switch
assembly 40 causes a pulse to be applied through signal conditioning pulse
circuit 125 and
OR gate 108 to reset TEST SUCCESSFUL LATCH 106, through OR gate 114 to reset
the
TEST CYCLE LATCH 100, and through OR gate 112 to condition TEST FAIL LATCH
111 to a SET state. Thus, a high water condition for any reason results in the
red
illumination of indicator 84 while the amber and green illuminations of
indicator 84 are
extinguished, and in the event of an active test cycle, valve 33 is closed to
prevent any
further fresh water from being admitted to sump container 11.
[0080] The system includes a conventional low voltage power supply 126 for
supplying
12 VDC operating power to solenoid-actuated valve 33 and to the various
functional
circuits of the controller. Power supply 126 includes a rechargeable battery
127 to supply
operating power to the control module component in the event of AC power
failure.
During normal operation AC power is supplied to power supply 126 through AC
power
cable 44 and an internal protective fuse 128.
17
CA 2931191 2017-10-18
[0081] The status of TEST FAIL LATCH I 1 1 and TEST SUCCESSFUL LATCH 106
is provided to the external communications module 50 (not shown in FIG. 9)
through
connector 48. Additional status information, including the serial number of
the system and
the time and nature of an event occurrence, can also be provided to the
communications
module through this connector.
[0082] Referring to FIG. 10, many of the functions heretofore described
with respect to
FIG. 9 can be more efficiently accomplished by a microprocessor implementation
of the
control system. In particular, a single microprocessor 129 can be provided
with the
various sensing and control inputs previously described and programmed to
carry out the
logic and timing functions required by the system. Previously described
outputs to the
green, red and amber indications of indicator 84 can be provided by the
processor as well,
as can the necessary data required for bi-directional communication through
communication port 48 to the external communications module 50 (not shown in
FIGS. 9
and 10). The programming of microprocessor 129 is well within the capabilities
of one
skilled in the art of microprocessors and the preparation of associated
firmware and
software.
[0083] The test and monitoring system described in the disclosure can also
be
effectively utilized to test and monitor a dual sump pump installation 130.
Referring to
FIG. 11, in a dual sump pump installation, a second motor driven sump pump 131
is
provided in sump container 11, typically at a slightly higher level than the
first motor
driven pump 13. Pump 131, like previously described pump 13, may include an
integral
float switch 132 which initiates operation of pump 131 when the water level in
container
11 rises to a fourth predetermined level IA. Float switch 132 discontinues
operation of
pump 131 when, as a result of pump 131 discharging water from sump container
11, the
water level in container 11 falls to a predetermined lower level L5. As with
sump pump
13, second sump pump 131 has a discharge pipe 133 through which pump 131
discharges
water from container 11. A power cord 134 is provided together with circuitry
associated
with internal pump float switch 132 to power pump 131. Additional support
bricks 14 may
be provided to raise pump 131 to a level higher than that of the pump 13 so
that in normal
operation pump 131 only operates in the event of failure of pump 13.
18
CA 2931191 2017-10-18
[0084] In accordance with the present disclosure, test and monitoring
system 130
includes additional components and circuitry to enable the system to test and
monitor the
two sump pumps in a manner similar to that of previously described single sump
pump
test and monitor system 30. Referring to FIGS. 11 and 12, test and monitoring
system 130
includes a control module 136 similar to the control module 31 of system 30,
except that
the module includes a second status indicator light 137 for indicating the
operating status
of the second sump pump 131, and a second AC receptacle 138 for receiving an
AC plug
associated with the power cord 134 of pump 131. This control module 136 is
intended to
be mounted on a flat supporting surface in the same manner as the previously
described
control module 31. Power is supplied to control module 135 by a power cord 44
in the
manner previously described and a communication module 50 (not shown) may be
connected to connector 48 as previously described. In addition, solenoid-
actuated valve
assembly 32 is connected by cable 38 to connector 45, and float switch
assembly 40, set at
predetermined high water level L3 (which is higher than predetermined water
trigger level
IA of pump 131), is connected by cable 42 to connector 46. Operation of
control module
136 is identical to that of the previously described control module 31 with
the exception of
the previously identified provision of indicator 137 and receptacle 136 to
accommodate
the second sump pump 131.
[0085] The operation of dual pump test and monitoring system 130 is
illustrated in the
simplified functional block diagram of FIGS. 13A and 13B. As shown in that
figure, the
system performs two test cycles in sequence--one for pump 13 and one for pump
131--and
separately indicates the success or failure of each test cycle by means of the
separate tri-
color indicators 84 and 137.
[0086] The pump 13 is tested in the manner previously described in
connection with
test and monitoring system 30. As before, the occurrence of the first test
cycle is governed
by TEST CYCLE LATCH 100 which transitions to a SET state during the occurrence
of a
test cycle, and to a RESET state in the absence of a test cycle. TEST CYCLE
LATCH 100
is periodically conditioned to a SET state by EVENT TIMER 101, which provides
a
momentary output signal after a predetermined time interval has lapsed
following the most
recent input applied to the timer. EVENT TIMER 101 may be set, for example, to
generate
19
CA 2931191 2017-10-18
a momentary output signal following a predetermined period of time, for
example, seven
days, or a like period after receipt of the most recent input signal, in
either case the first
test cycle (and the second test cycle of system 130), will occur at periods of
not more than
seven days. As before, it will be appreciated that a greater or lesser test
interval may be
set by EVENT TIMER 101 as desired by the user.
[0087] When TEST CYCLE LATCH 100 is in a SET state, a signal is also
applied
through AND gate 102 and solenoid driver circuit 103 to solenoid 52 of valve
assembly 33
to condition the valve assembly to admit water to sump container 11. Water
continues to
be admitted until either TEST CYCLE LATCH 100 reverts back to a RESET state,
as in
the case of a successful test, or the high water float switch assembly 40 or
another failure
provides a signal to AND gate 102, in the case of an unsuccessful test.
[0088] When TEST CYCLE LATCH 100 is in a SET state, it provides an output
signal
which provides for an amber illumination by indicator 84. Also, TEST CYCLE
LATCH
100 in its SET state resets TEST SUCCESSFUL LATCH 106, and TEST FAIL LATCH
111. This terminates the output of these components such that during a test
cycle indicator
84 can only present an amber illumination.
[0089] As before, the output of TEST CYCLE LATCH 100 is also applied to
TEST
CYCLE TIMER 110 which times the duration of the test cycle and provides a
momentary
timeout output signal in the event the SET state of TEST CYCLE LATCH 100, and
hence
the test cycle of pump 13, exceeds a predetermined maximum time duration. In
the event
of this timeout, TEST CYCLE TIMER 110 conditions TEST FAIL LATCH 111 to a SET
state, causing a red illumination of indicator 84. Also, the output of TEST
CYCLE TIMER
110 causes TEST CYCLE LATCH 100 to be reset, thereby terminating the test
cycle and
extinguishing the amber illumination of indicator 84. The output of TEST FAIL
LATCH
111 also conditions ALARM LATCH 115 to a SET state, thereby causing an audible
alarm
to occur. ALARM LATCH 115 can be reset by momentary actuation of RESET switch
87
in the manner previously described. RESET switch 87 also causes, through delay
circuit
117, when held for an extended period of time, the reset of TEST CYCLE LATCH
100,
TEST FAIL LATCH 111, and TEST SUCCESSFUL LATCH 106, as well as the to be
CA 2931191 2017-10-18
described counterpart components associated with pump 131, thereby
conditioning the
system for a subsequent test of the two pumps. As before, a manual test of the
first sump
pump 13 can be initiated by TEST switch 85 through signal conditioning circuit
119 and
OR gate 120.
[0090] The output of MOTOR CURRENT SENSOR 121 may provide a reset signal
through signal conditioning circuit 122 to EVENT TIMER 101, causing that timer
to begin
a new timing period with each operation of the motor. The output of MOTOR
CURRENT
SENSOR 121 is also applied to signal conditioning circuit 123, which provides
a
momentary pulse upon the motor stopping. This pulse, signaling the completion
of a
successful test, is applied through OR gate 114 to reset TEST CYCLE LATCH 100
to
terminate the test cycle. The same motor stop pulse also serves to condition
TEST
SUCCESSFUL LATCH 106 to a SET status to indicate a successful test of sump
pump 13
by illuminating the green indication of indicator 84. A further function of
motor current
sensor 121 is to initiate a timeout period in MOTOR RUN TIMER 124. In the
event pump
13 operates continuously for a period exceeding the timeout period of MOTOR
RUN
TIMER 124, the timer generates an output signal which resets TEST CYCLE LATCH
100
and conditions TEST FAIL LATCH 111 to a SET state. This causes the red
illumination
of indicator 84. Also, the output of MOTOR RUN TIMER 124 resets TEST
SUCCESSFUL LATCH 106 to extinguish the green illumination of indicator 84
driven by
that latch.
[0091] In the event sump pump 13 fails to operate, the eventual closure of
high water
sensing switch assembly 40 causes an inhibit signal to be applied to AND gate
102,
preventing further operation of solenoid 82 and further fresh water from being
admitted to
sump container 11. Also, as before, the closure of high water level switch
assembly 40
causes TEST SUCCESSFUL LATCH 106 and TEST CYCLE LATCH 100 to be
conditioned to a RESET state, and TEST FAIL LATCH 111 to be conditioned to a
SET
state. Thus, a high water condition results in no further water being admitted
through
valve 33 to sump container 11 and any amber and green illuminations of
indicator 84 are
extinguished while causing a red illumination of indicator 84.
21
CA 2931191 2017-10-18
[0092] As with the control module of system 30, the control module of
system 130
includes a conventional low voltage power supply 126 for supplying operating
power to
solenoid-actuated valve 33 and the various functional circuits of the
controller. Power
supply 126 includes a rechargeable battery 127 to supply operating power to
the control
module component in the event of AC power failure. During normal operation AC
power
is supplied to power supply 126 through AC power cable 44 and an internal
protective
fuse 128.
[0093] The status of TEST FAIL LATCH I 1 1 and TEST SUCCESSFUL LATCH 106
as to sump pump 13 is provided to external communications module 50 through
connector
48. Additional status information, including the serial number of the system
and the time
and nature of an event occurrence, can also be provided to the communications
module
through this connector.
[0094] To accommodate testing and monitoring of the second sump pump 131,
one
embodiment of the dual pump test and monitoring system 130 of the disclosure
incorporates additional circuitry within control module 136. As shown in FIGS.
13A and
13fl, the occurrence of a test cycle for the second pump 131 is determined by
a second
TEST CYCLE LATCH 140 (FIG. 13B) which transitions to a SET state during the
occurrence of a test cycle for pump 131, and to a RESET state in the absence
of such a test
cycle.
[0095] In accordance with the present disclosure, TEST CYCLE LATCH 140 is
conditioned to a SET state by TEST CYCLE LATCH 100 upon that device completing
a
test cycle for sump pump 13. To that end, the output of the latch is applied
to the SET
input of latch 140 through a signal conditioning pulse circuit 93.
[0096] When TEST CYCLE LATCH 140 is in a SET state, a signal is applied
through
AND gate 142 and solenoid driver circuit 143 to the solenoid 52 of valve
assembly 33 to
cause the valve assembly to admit fresh water to sump container 11. Fresh
water continues
to be admitted until either TEST CYCLE LATCH 140 reverts back to a RESET
state, as in
the case of a successful test, or the high water float switch assembly 40
provides an inhibit
signal to AND gate 142, in the case of an unsuccessful test.
22
CA 2931191 2017-10-18
[0097] When TEST CYCLE LATCH 140 is in a SET state, it also provides an
output
signal which provides an amber illumination by indicator 137 through AND gate
144 and
LED driver 145. Also, the TEST CYCLE LATCH 140 in its SET state resets a TEST
SUCCESSFUL LATCH 146 through a signal conditioning pulse circuit 147 and OR
gate
148. This terminates the output of TEST SUCCESSFUL LATCH 146 such that the
green
illumination of indicator 137 driven through LED driver 149 is extinguished.
Thus, only
the amber illumination of indicator 137 is present during a test cycle.
[0098] The output of TEST CYCLE LATCH 140 is also applied to a TEST CYCLE
TIMER 150 which times the duration of the test cycle and provides a momentary
timeout
output signal in the event the SET state of TEST CYCLE LATCH 140, and hence
the test
cycle of pump 131, exceeds a predetermined maximum time duration. In the event
of this
timeout, TEST CYCLE TIMER 150 conditions TEST FAIL LATCH 151 to a SET state
through an OR gate 152. This causes the red illumination of indicator 137
through AND
gate 155 and LED driver 153. Also, the output of 'FEST CYCLE TIMER 150 causes
TEST
CYCLE LATCH 140 to be reset by means of a signal provided through OR gate 154,
thereby extinguishing the amber illumination of indicator 137. The output of
TEST FAIL
LATCH 151 also conditions ALARM LATCH 115 to a SET state through a signal
conditioning pulse circuit 156 and OR gate 97, thereby causing an audible
alarm to occur.
Alarm latch circuit 115 can be reset by momentary actuation of RESET switch
87, in the
manner previously described. RESET switch 87 also causes, through delay
circuit 117,
when held for an extended period of time, the reset of TEST CYCLE LATCH 140,
TEST
FAIL LATCH 151, and TEST SUCCESSFUL LATCH 146, thereby conditioning the
system for a subsequent test of pump 131. A manual test of the first and
second pumps can
be initiated by TEST switch 85 through signal conditioning circuit 119 and OR
gate 120.
[0099] The output of MOTOR CURRENT SENSOR 161 is applied to signal
conditioning pulse circuit 163, which provides a momentary pulse upon the
motor
stopping. This pulse, signaling the completion of a successful test, is
applied through OR
gate 154 to reset TEST CYCLE LATCH 140 to terminate the test cycle for second
pump
131. The same motor stop pulse also serves to condition TEST SUCCESSFUL LATCH
146 to a SET status to indicate successful completion of a test cycle by
illuminating the
23
CA 2931191 2017-10-18
green indication of indicator 137. A further function of motor current sensor
161 is to
initiate a timeout period in MOTOR RUN TIMER 164. In the event pump motor 113
operates continuously for a period exceeding the timeout period of MOTOR RUN
TIMER
164, the timer generates an output signal which resets TEST CYCLE LATCH 140
through
OR gate 154 and conditions TEST FAIL LATCH 151 to a SET state through OR gate
152.
This causes the red illumination of indicator 137 through LED driver 153.
Also, the output
of MOTOR RUN TIMER 164 resets TEST SUCCESSFUL LATCH 146 through OR gate
148 to extinguish the green illumination of indicator 137 driven by that latch
through LED
driver 149.
[00100] In the event pump motor 131 fails to operate, the eventual closure of
high water
sensing switch assembly 40 causes an inhibit signal to be applied to AND gate
142,
preventing further operation of solenoid 52 to prevent further fresh water
from being
admitted to sump container 11. Also, the closure of high water level switch
assembly 40
causes a pulse to be applied through signal conditioning pulse circuit 165 and
OR gate 148
to reset TEST SUCCESSFUL LATCH 146, and through OR gate 154 to reset TEST
CYCLE LATCH 140, and through OR gate 152 to condition TEST FAIL LATCH 151 to a
SET state. Thus, a high water condition results in no further water being
admitted through
valve 33 to sump container 11 and any amber and green illuminations of
indicator 137 are
extinguished while causing a red illumination of indicator 137. As previously
described in
connection with the single pump system 30, a FLASHER CIRCUIT 172 may be
provided
to cause a flashing red illumination of indicator 137 prior to actuation of
RESET switch
87, and a FLASHER CIRCUIT 173 may be provided to cause a flashing amber
illumination of indicator 137 when TEST CYCLE LATCH 140 is SET and valve 33 is
open.
[00101] The status of TEST FAIL LATCH 151 and TEST SUCCESSFUL LATCH 146
is provided to external communications module 50 (not shown in FIG. 13)
through
connector 48. Additional status information related to pump 131, including the
time and
nature of an event occurrence, can also be provided to the communications
module
through this connector.
24
CA 2931191 2017-10-18
[00102] To provide for sequential testing of pumps 31 and 131, the AC supply
circuit to
the pump motors includes single pole normally closed relays 168 and 169 and
associated
respective relay driver circuits 170 and 171. When TEST CYCLE LATCH 100 is in
a SET
state to test the motor of pump 13, relay 168 associated with pump 131 is
energized open,
preventing the motor of pump 131 from operating. Subsequently, when TEST CYCLE
LATCH 140 is in a SET state to test the motor of pump 131, relay 169
associated with
pump 13 is energized open, preventing the operation of the motor of pump 13.
Thus, each
motor of each pump is independently tested.
[00103] Referring to FIG. 14, many of the functions heretofore described with
respect to
FIG. 13 can be more efficiently accomplished by a microprocessor
implementation of the
control system. In particular, a single microprocessor 180 can be provided
with the
various sensing and control inputs previously described and programmed to
carry out the
logic and timing functions required by the system. Previously described
outputs to cause
the green, red and amber illuminations of indicators 84 and 137 can be
provided by
processor 180 as well, as can the necessary data required for hi-directional
communication
through communication port 48 to external communications module 50 (not shown
in
FIGS. 13 and 14). The programming of microprocessor 180 is well within the
capabilities
of one skilled in the art of microprocessors and the preparation of associated
firmware and
software.
[00104] Thus, each of the two pumps 13 and 131 in sump container 11 is
individually
monitored and the successful or unsuccessful test of each pump is separately
indicated.
Additional reporting is provided to communications module 50 to indicate the
status of
each pump. Visual and aural warnings are given in the event that either pump
13 or pump
131 is inoperative. Thus, the dual pump system 130, like the single pump
system 30, is
fully automated and proactively provides the user with a warning of pump
failure prior to
the pump actually being required for evacuating ground water from the pump
reservoir. As
before, it is contemplated that additional functions, such as power failure or
low battery,
or a low temperature condition in the environment of the pump system can also
be
communicated by means of the communications module. The communications module
may communicate with the user by means of an internet connection, a cellular
data
CA 2931191 2017-10-18
connection, a phone connection, or by means of a hardwired connection to a
separate
building alarm system, to the owner or one or more persons designated by the
owner of
the system.
[00105] The information given to the user can include the time and date of the
successful tests, the time and date of unsuccessful tests and additional
information such as
power failure or temperatures falling below a predetermined level. The
information can be
copied or redirected to multiple destinations and users, including plumbing
and property
management services. The system can be readily installed in conventional
single and dual
sump pump installations without modification to the pump mechanisms, or the
physical
construction of the pump reservoir or associated plumbing. Moreover, the
system is the
completely fail safe in that the monitored pumps will continue to operate in a
normal
manner in the event of removal or complete inoperability of the test and
monitoring
system.
[00106] The sump pump test and monitoring systems described in this disclosure
can
also be adapted to monitor sump pump installations which utilize a battery-
powered DC
sump pump. One such system, which includes additional enhancements to the
valve
module 32 and liquid level sensor module 40, is shown in FIG. 15.
[00107] The system 200 tests and monitors a DC-powered pump 201 having a
conventional float switch 202 which causes the pump to operate when the liquid
level in
sump container reaches level Li, and terminates pump operation when the liquid
level in
the container falls to level L2 as a result of the pump discharging water
through discharge
pipe 17. Pump 201 is connected to and receives DC operating power from a
conventional
battery 203 through a two conductor cable 204. The battery is maintained
charged by an
AC-powered charger 205, which receives AC operating power through an AC line
cord
206 having a conventional end plug inserted into receptacle 43 of a test
control module
207, which is similar to the previously described test control module 31
utilized with AC-
powered sump pump 13. Test control module 207 is connected to an AC receptacle
by an
AC line cord 44.
[00108] To monitor the current drawn by DC motor 201, system 200 includes a
current
26
CA 2931191 2017-10-18
probe module 210 which clamps over one of the conductors in cable 204 which
supplies
current to motor 201. Current probe module 210 is connected to a connector 212
on
control module 207 by a cable 211, which provides a signal to the circuitry of
control
module 207 which indicates the current supplied by battery 203 to the motor.
[00109] When conducting a test, test and monitoring system 200 supplies an
actuating
signal to valve module 33 through cable 38, causing fresh water to be admitted
to sump
container 11. When the liquid level in the container rises to level Li, motor
201 operates.
This increase in current the motor is detected by current probe module 210,
and hence
control module 207, causing the control module to terminate the actuating
signal to valve
33 to stop the flow of fresh water into the container. As liquid is evacuated
from container
11 by pump 201, the liquid level falls to L2, and the pump stops. The
termination of
current to the motor is interpreted as a successful test by control module
207, resulting in
pump status indicator 84 lighting a steady green to indicate a successful
test.
[00110] Should sump pump 201 fail to function, the liquid level in the sump
reservoir
will continue to rise to level L3, causing a high liquid level sensor module
213 to send a
signal to control module 207 through cable 42. This causes control module 207
to
interrupt the actuating signal to valve 33 to terminate water flow into the
sump container
and cause LED indicator 84 to light red, indicating a pump failure. As in the
previously
described sump pump test and monitoring system, a communications module 50
connected
to control module 207 by a cable 49 may provide notification of the pump
failure at one or
more user-designated remote locations.
[00111] Referring to FIG. 16, sump pump test and monitoring system 200
incorporates
an improved valve module 214 which provides additional valve monitoring
functionality
to the system. In particular, valve module 214 includes, in addition to the
solenoid valve
33, a liquid flow sensor 215 which generates a signal indicating of the actual
flow rate of
fresh water through the valve. This signal is communicated through a cable 216
to a
dedicated connector 217 on control module 207. In accordance with another
aspect of the
disclosure, circuitry within the control module utilizes the flow rate to
confirm the proper
operation of valve 33. When control module 207 applies an actuating signal to
the valve,
27
CA 2931191 2017-10-18
the output signal from flow sensor 215 is utilized to confirm that the valve
has opened and
that fresh water is entering the sump container. When the actuating signal is
removed from
the valve, closure of the valve and termination of fresh water flow is
confirmed by the
output signal of the flow sensor indicating no flow. In the event that either
valve condition
is not confirmed by the flow sensor, any test in progress is terminated and a
valve fault is
signaled by control module 207. As with valve module 32, a cover 56 is secured
over the
valve and flow sensor to protect the assembly from damage.
[00112] The improved liquid level sensor module 213 utilized in sump pump test
and
monitoring system 200 is illustrated in FIGS. 18 and 19. As with the
previously described
sensor module 40, module 213 is mounted by a bracket 41 secured to discharge
pipe 17 by
a block 65 and strap 67. A generally cylindrical housing 68 having a plurality
of
perforations 71 forms a compartment 70. Within this compartment, two donut-
shaped float
members 75 and 220, each having an internal toroidal permanent magnet (not
shown), are
arranged to slide along a hollow non-magnetic stem 73 within which two
magnetically-
actuated reed switches 74 and 221 are positioned, one above the other. Float
member 75 is
constrained to slide between two fixedly-positioned washers 76 and 77 as the
liquid level
in the container rises. Reed switch 74 is positioned within stem 73 such that
the magnet in
member 75 actuates the switch when the member reaches washer 77. Similarly,
float
member 220 is constrained by fixedly positioned washers 222 and 223 so that
reed switch
221 is actuated by the magnet in float member 220 when the rising liquid level
causes that
member to reach washer 223. As will be described subsequently in conjunction
with FIG.
28, the presence of the independently connected switches achieves, in
accordance with
another aspect of the disclosure, self-monitoring and redundancy in liquid
level sensor
module 213 for improved reliability.
[00113] Referring to FIG. 20, test control module 207 is seen to include an
additional
socket 217 for connecting to flow transducer 215 through cable 216, and an
additional
socket 212 for connecting to current probe module 210 through cable 211. In
addition,
module 207 includes two mode-indicating blue LEDs 225 and 226 which indicate
the
operating mode of the controller, LED 225 indicating when lit that the
controller is
configured to test and monitor an AC sump pump connected to receptacle 43 by
means of
28
CA 2931191 2017-10-18
an internal current sensor 121 (FIG. 22) associated with the receptacle, and
LED 226
indicating when lit that the controller is configured to test and monitor a
battery-powered
DC pump connected to receptacle 43 by means of external current probe 210.
Except for
the additions, control module 207 is essentially identical to the previously
described
control module 31. And, as with control module 31, the housing of control
module 207
can be alternatively adapted for mounting to the pump discharge pipe 17, as
shown in FIG.
21.
[00114] Referring to FIG. 22, sump pump test and monitoring system 200 is seen
to be
structurally and functionally similar to system 30, except for the improved
liquid level
sensing module 213, the improved valve module 214, current probe 210 and the
additional
components required to implement these features and monitor a battery-powered
DC
pump. In particular, switches 74 and 221 of liquid level sensing module 213
are connected
to a sensing module monitor circuit 230, wherein the sequencing of the
switches is
monitored and a fault signal is produced for inhibiting operation of valve 33
and for
lighting an LED indicator 231 in the event of a malfunction. This monitoring
circuitry is
described in detail in connection with FIG. 28.
[00115] Furthermore, valve module 214 requires additional valve-monitoring
circuitry
232 to receive the output of flow sensor 215 and compare that with the status
of valve 33.
In the event of no flow when the valve is actuated open, or in the event of
flow when the
valve is not actuated open, fault signals are generated which illuminate an
LED 233 and
inhibit the further application of an actuating signal to the valve. An
additional protective
circuit 234, described in conjunction with FIG. 34, may be provided with valve
driver
circuit 103 to prevent the valve from being inadvertently actuated in the
event of a
malfunction in other components, including processor 240 (FIG. 23), for the
reliable
operation of valve 33.
[00116] To provide for motor current being sensed by current probe module 210
when
the system is monitoring a battery-powered DC motor, a two-pole two-position
mode
switch 235 switches between the internal sensor 121 associated with receptacle
43 and the
external current probe module 210. Indicators 225 and 226 are correspondingly
29
CA 2931191 2017-10-18
illuminated by this switch to indicate the mode selected. It is intended that
mode switch
235 will be set by the installer of system 200 by sequential actuation of a
mode select push
button switch (241) at the time of installation.
[00117] Referring to FIG. 23, the sump pump test and monitoring system 200
described
in FIG. 22 can be efficiently implemented using a microprocessor 240. In this
implementation, push-button switch 241 is utilized to switch between the AC
pump
monitoring mode and the DC pump monitoring mode, in the manner of mode switch
235
(FIG. 22). Also, another push-button switch 242 may be optionally provided to
initialize
the system, in a manner to be described in conjunction with FIG. 31. Processor
240 can be
programmed using conventional programming techniques by someone of ordinary
skill in
the computer programming arts.
[00118] Referring to FIG. 24, in accordance with another aspect of the
disclosure, a
sump pump test and monitoring system 250 is shown which simultaneously tests
and
monitors AC pump 13 and battery-powered DC pump 201. The system, except for
the
provision for DC pump 201, and the previously described improved liquid level
sensor
module 213, the previously described improved valve module 214 and the added
current
probe 210, and additional circuitry required to implement these features, is
essentially
similar to the previously described test and monitoring system 130. As shown
in FIGS. 24
and 25, the control module 251 of the system includes a receptacle 138 for
supplying
power to a second pump, or in this case, to battery charger 205, and two
connector sockets
212 and 217, for connecting to current probe module 210 and flow sensor 215,
respectively. A second LED status indicator 137 is provided to indicate the
status of a
sump pump connected to receptacle 138. Push button switches 241 and 242
provide mode
select and initialize functions, respectively. In the mariner of the
previously described
control module 207, AC and BAT (DC) mode indicating LEDs are provided in
association
with AC receptacles 43 and 138. A pair of blue LED indicators 225 and 226
associated
with receptacle 43, and a pair of blue LEDs 252 and 253 associated with
receptacle 138,
indicate AC and BAT (DC) modes, respectively.
[00119] Referring to FIGS. 26A and 26B, the structure and functionality of
sump pump
CA 2931191 2017-10-18
test and monitoring system 250, except for the previously stated changes and
additions, is
similar to that of system 130. In particular, system 250 includes a two
position mode
selector switch 254 provided to select either AC or BAT modes for receptacles
43 and
138. Mode selector switch may include additional switch sections to actuate
LED
indicators 225, 226, 252 and 253 in accordance with the selected monitoring
mode. In
practice, various combinations of mode designations may be provided for the
receptacles,
such as, for example, AC or BAT for receptacle 43 with receptacle 138 not
used, or AC
for receptacle 43 and receptacle 138, or AC for receptacle 43 and BAT for
receptacle 138.
These selections can be accomplished by repeated momentary actuations of mode
select
switch 241 (FIG. 27).
[00120] As shown in FIG. 27, the functions of control module 251 in sump pump
test
and monitoring system 250 can be efficiently accomplished by utilizing a
microprocessor
255. Processor 255 can be programmed using conventional programming techniques
by a
programmer of average skill in the computer programming arts.
[00121] Thus, system 250 as implemented in FIGS. 25-27 provides test and
monitoring
capability for both AC and battery-powered DC pumps in both single and dual
pump
installations. The system will automatically and periodically test installed
pumps,
providing an unambiguous indication of the status of each pump.
[00122] Referring to PIG. 28, the dual float switches 74 and 221 provided in
liquid level
sensor module 213 provide, in combination with a monitoring circuit 230,
protection
against a float switch failure. In particular, reed switch 74 is connected
through a signal
conditioning pulse circuit 260 to a timer 261. After a first predetermined
time out period,
slightly in excess of the time nominally required for the liquid level in the
sump container
13 to rise from a level actuating switch 70 to a level actuating switch 221,
timer 261
provides an output pulse which conditions a latch circuit 262 to a SET state.
Similarly,
reed switch 221 is connected through a signal conditioning pulse circuit 263
to a timer
264, which after a very short predetermined time out period provides an output
pulse to
condition a latch circuit 265 to a SET state.
[00123] During a test cycle, as the liquid level in sump container 11 rises
switch 74 is
31
CA 2931191 2017-10-18
eventually actuated, conditioning latch 262 to a SET state after the time out
period of
timer 261. In the meantime, as the liquid level continues to rise switch 221
is actuated and
latch 265 is conditioned to SET, after a much shorter delay period set by
timer 264. If
switch 221 has not actuated by the time out of latch 262, indicating a failure
of switch
221, an AND gate 266 provides a sensor fault signal through an OR gate 267 and
a signal
conditioning pulse circuit 268. At the same time, the output of latch 262
provides a high
liquid level output signal through an OR gate 270, short delay timer 271 and
signal
conditioning pulse circuit 272. In the event switch 221 is activated by the
rising liquid
level in sump container 11 but switch 74 has not been actuated, after the
short time out
period of timer 264 latch 265 is set and a sensor fault output is provided
through an AND
gate 273, OR gate 267 and signal conditioning pulse circuit 268. At the same
time, the
output of latch 265 provides a high liquid level output signal through OR gate
270, timer
271 and signal conditioning pulse circuit 272. Thus, with the monitoring
circuit 230,
failure of either one of the two reed switches 74 and 221 of liquid level
sensor 213 is
detected and signaled to the user, and the remaining switch provides a high
liquid level
output signal which terminates the test cycle by closing valve 33 and
signaling a pump
failure by conditioning the associated status LED to a red indication. The
functionality of
valve monitoring circuit 230 can be most advantageously implemented within a
microprocessor-based system such as those shown in FIGS. 1, 14, 23 and 27.
[00124] Referring to FIGS. 29 and 30, the current sensing probe module 210
utilizes a
solid state current sensing element 280, such as a Hall Effect sensor IC,
positioned in
close proximity to one of the electrical conductors 282 in cable 204 supplying
DC current
from battery 208 to DC motor 201. The Hall Effect sensor responds to the
magnetic field
around the conductor, the magnitude and direction of the field being dependent
on the
magnitude and direction of current flow in the conductor. A regulated
reference voltage
developed by a conventional voltage regulator 281 is supplied to the sensor,
which
provides an analog output voltage either greater or lesser than the reference
voltage,
depending on the magnitude and direction of current flow in the conductor. The
analog
output voltage is filtered by a resistor 283 and a capacitor 284 and supplied
through cable
211 (FIG. 15) to circuitry within control module 207. As shown in FIG. 30, the
circuitry
of probe 201 is preferably contained within a housing 285 which includes an
internal
32
CA 2931191 2017-10-18
toroidal magnetic element 286 that wraps around conductor 280 and includes two
air gaps
that facilitate installation on the conductor without disconnecting the
conductor from
battery 203. Sensing element 280 is positioned close to one of these gaps such
that a
portion of the magnetic flux surrounding the conductor is sensed by the
sensing element.
[00125] Thus, a compact and easily removable probe is provided that can sense
DC
motor current as required to confirm operation of the battery-powered sump and
provide a
current-indicative signal to circuitry within the system controller.
[00126] Referring to FIG. 31, the time out period for a test cycle can, in
accordance with
another aspect of the disclosure, can optionally be adjusted in accordance
with the actual
flow rate of fresh water into pump container 11 during a test cycle. To this
end, with all
sump pumps disconnected or otherwise disabled, and with no significant flow of
ground
water into the container, an initialize circuit 290 is actuated by momentary
actuation of
INITIALIZE push button switch 242. This causes valve 33 in valve module 214 to
begin
admitting water to the sump container and a timer 291 to be actuated. Timer
291 continues
to run until stopped by an output signal from high liquid level sensing module
230. The
elapsed time, as indicated by timer 291, upon timer 291 stopping becomes the
base fill
time for the sump container.
[00127] During the same inflow period, flow sensor 215 provides an output
signal
indicating the then existing flow rate of fresh water into the sump container
11. This flow
rate is stored in a memory component 292. During subsequent test periods this
stored flow
rate is compared with the actual flow rate by a processor 293 to obtain a flow
correction
factor, and from that factor a test time out correction factor is calculated.
This time out
correction factor is added to or subtracted from the base time out by a
correction circuit
294 to obtain a corrected time out period for use in subsequent sump pump
testing.
[00128] Use of the corrected time out period compensates for variations in the
flow rate
of fresh water into the sump container as might result from pressure
variations in the fresh
water supply. This can reduce the test cycle time out during periods of high
water pressure
and high fresh water flow rate, thereby reducing the time required for the
test, and
increase the test cycle time out during periods of low water pressure and low
fresh water
33
CA 2931191 2017-10-18
flow rate, thereby in extreme cases avoiding a false indication of pump
failure from a
premature time out, before the liquid level in the container has reached the
actuating level
of the pump under test. The functionality of the described variable time out
circuit can be
most advantageously implemented within a microprocessor-based system such as
those
shown in FIGS. 1, 14, 23 and 27.
[00129] Referring to FIG. 32, in further accord with the present disclosure,
previously
described sump pump test and monitoring systems 200 and 250 can optionally
track the
performance of monitored sump pumps. In particular, a memory component 300
provided
in the system control module can record for each test the date and time, as
provided by an
internal calendar component 301, the duration of the test cycle as provided by
a timer
circuit 302, and the current supplied to the motor under test as provided by
the internal AC
sensor 303, in the case of an AC motor, or by the DC current probe module 210,
as
appropriately selected by an internal switch 304, in the case of a battery-
powered DC
motor.
[00130] Periodically, an internal processor 305, which can be the main control
processor
of the module, receives and processes the test information stored in memory
component
300 and produces a report, which is conveyed over the existing communications
channel
306 to the owner of the system and other owner-designated recipients, such as
the owner's
plumbing contractor. In this way, an impending failure of a monitored sump
pump. as
recognized by a longer elapsed run time, or by higher or lower motor current
consumption,
can be recognized and pre-emptive repair or replacement action can be taken.
The
functionality of the described trend monitoring and reporting system can be
most
advantageously implemented within a microprocessor-based system such as those
shown
in FIGS. 1, 14,23 and 27.
[00131] Referring to FIG. 33, in accordance with another aspect of the
disclosure, the
communication channel can be optionally utilized to initiate a test of the
monitored sump
pump installation in advance of an impending weather event. In particular, a
control signal
initiated from a central monitoring location, or alternatively a control
signal automatically
initiated by a computerized weather monitoring system, can, in reaction to a
serious storm
34
CA 2931191 2017-10-18
or other threat, address one or more sump pump test and monitoring systems in
a selected
threat region to initiate a test of the sump installations monitored by those
systems.
[00132] To this end, a command signal is sent over the existing bi-directional
communication channel 311 to communication circuitry 312 within the control
modules of
each addressed monitoring system. This command signal is conveyed through a
system
address filter 313, which compares the command signal with a stored unit
address in a
memory 314. If a match exists, the command signal is recognized and a control
signal is
applied through a conditioning pulse circuit 315 to condition test cycle latch
310 to a SET
state, thereby starting a test cycle in the designated test and monitoring
system.
[00133] Once the test cycle is initiated, the test continues until a result is
obtained,
which is conveyed back over the communications channel to the monitoring
center and
other owner-designated recipients in a conventional manner. Successful receipt
of the test
command can also be conveyed back to the originator by a signal conditioning
circuit 316
if desired. Thus, extreme weather events involving heavy rainfall can be
protected against
by selective proactive testing of sump pump installations likely to experience
the events.
The functionality of the described remote activation system can be most
advantageously
implemented within a microprocessor-based system such as those shown in FIGS.
1, 14,
23 and 27.
[00134] Referring to FIG. 34, to preclude the fresh water valve 33 from being
actuated
by a failure in processor 255, the sump pump test and monitoring systems
previously
described can, in accordance with another aspect of the disclosure, be
optionally provided
with a protection circuit 320. Utilizing this system, the valve actuating
signal generated by
the system processor for application to protective circuit 320 is, instead of
a simple
actuating signal, a square wave signal of predetermined frequency, or of some
other
complex waveform, possible only in the event of the processor operating
normally.
[00135] This complex signal is analyzed by the protective circuitry and if
determined to
be of the correct format, converted to a steady state control signal which is
applied to
solenoid 52 to open valve 33. Thus, in the event of a malfunction in
microprocessor 255,
the requisite complex valve control signal will not be supplied to the
protective circuit,
CA 2931191 2017-10-18
and no actuating signal will be applied to valve module 33. Thus, valve
protection circuit
320 functions to prevent valve 33 from being inadvertently actuated by a
processor
malfunction, thereby increasing the reliability of the system. The
functionality of the
described valve protection system can be most advantageously implemented
within a
microprocessor-based system such as those shown in FIGS. 1, 14, 23 and 27.
[00136] The foregoing detailed descriptions have been given for clearness of
understanding only and no unnecessary limitations should be understood
therefrom. It will
be apparent to those skilled in the art, that changes and modifications may be
made therein
without departing from the invention in its broader aspects, and, therefore,
the intent in the
appended claims is to cover all such changes and modifications that fall
within the true
spirit and scope of the present disclosure.
36
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