Note: Descriptions are shown in the official language in which they were submitted.
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PUMP COMMUNICATION MODULE, PUMP SYSTEM AND METHODS RELATING THERETO
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application
No. 62/433,772,
filed December 13, 2016, and U.S. Provisional Application No. 62/597,407,
filed December 11,
2017, both of which are hereby incorporated herein by reference in their
entirety.
FIELD OF TECHNOLOGY
[0002] The present disclosure generally describes a pump communication
module, a
pump system using same and methods relating thereto. More specifically, the
present
disclosure describes pump systems that have a secondary or redundant
communication
method, sump pumps that integrate a backup battery powered pumping system and
a
controller that provides status notification options via the redundant
communication setup,
as well as related methods.
BACKGROUND
[0003] Sumps are low pits or basins designed to collects undesirable
liquids such as
water around the foundation of a home. Water that seeps into the home from the
outside can
flow into the sump to prevent water from spreading throughout the home. If too
much water
seeps into the sump, a sump pump can be employed to move the water from the
sump to a
location outside the house.
[0004] A typical electric basement sump pump includes a pump to remove
water from
the sump basin, and various switches and related components that turn the pump
on and off
when appropriate, based on the water levels in the sump. Electric sump pumps
are generally
powered via an AC power source that plugs into a home's AC power supply.
[0005] Sump pump systems can also be equipped with audible alarm and/or
user
notification systems that transmit messages via text, e-mail, or a phone call
to a user in the
event of pump malfunction, power outage, or high water (flooding) conditions.
SUMMARY
[0006] The present disclosure describes pump communication modules that
allow for
redundant communication, sump pumps that integrate a backup powered sump pump
system into a primary powered sump pump and utilize such a communication
module and
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methods relating to same. The present disclosure also describes sump pumps
that integrate
control and notification systems that determine when to activate the backup DC
powered
sump pump system, and notify home owners regarding the operating status of the
integrated
pumping system. In addition to various exemplary embodiments, the present
disclosure
further covers methods related to the aforesaid embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[00071 Described herein are embodiments of systems, methods and apparatus
for
addressing shortcomings of known sump pumps.
[00081 This description includes drawings, wherein:
[00091 Figure 1A shows an isometric view of an example tandem sump pump
assembly
described herein.
[00101 Figures 1B and 1C show front and rear elevation views, respectively,
of the
tandem sump pump assembly of Figure 1.
[00111 Figures 1D and 1E show right and left elevation views, respectively,
of the tandem
sump pump assembly of Figure 1.
[00121 Figures 1F and 1G show top and bottom plan views, respectively, of
the tandem
sump pump assembly of Figure 1.
[00131 Figure 2A shows an example of a tandem sump pump assembly connected
to a
discharge pipe with an integrated control/power module.
[00141 Figure 2B is an up close view of the tandem sump pump assembly of
Figure 2A.
[00151 Figure 3 is a diagram demonstrating various functionality of an
integrated sump
pump control and battery charging system described herein.
[00161 Figures 4A-B are sketches showing an example of a sump pump in a
sump pit
with a pressure tube.
[00171 Figures 5A-B show examples of a warning notification and
communication
system described herein.
[00181 Figure 6 shows a top view of an exemplary configuration of a twin
volute
component of a tandem sump pump assembly.
[00191 Figure 7 is an example of a conventional DC powered backup sump
pump.
[00201 Figure 8 is a schematic diagram of an example control system for a
tandem sump
pump system described herein.
[00211 Figure 9 is a schematic diagram of a dual processor redundant backup
system for
a sump pump system described herein.
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[00221 Figure 10 is a schematic diagram of an alternate example of a
redundant controller
system as described herein.
[00231 Figure 11A is a schematic drawing of a redundant control system for
a dual sump
pump arrangement utilizing a processor and a software-free relay controller in
accordance
with examples described herein.
[00241 Figure 11B is a more detailed schematic of a redundant control
system for a dual
sump pump arrangement utilizing a processor and a dual switch software-free
relay
controller in accordance with examples described herein.
[00251 Figure 11C is a sketch of a redundant switch used in accordance with
examples of
redundant control systems described herein.
[00261 Figure 12 is a schematic drawing of a system that allows two
separate pumping
systems to communicate with one another in accordance with examples described
herein.
[00271 Figures 13A-G show various views of an alternate exemplary tandem
sump pump
assembly with cross-over piping and associated check valves extended at a
height above the
sump pumps and/or above the sump pit in order to simplify service of same in
accordance
with examples described herein.
[00281 Figure 14 is a bottom view of an exemplary embodiment of a sump pump
assembly where the two sump pumps are of different sizes in accordance with
examples
described herein.
[00291 Figure 15 shows an example of a tandem sump pump system that
utilizes two
separate discharge lines without a crossover pipe in accordance with examples
described
herein.
[00301 Figure 16A shows an exemplary sump pump assembly with a bracket that
cuffs
the two pumps together in accordance with examples described herein.
[00311 Figure 16B shows the bracket of the assembly of Figure 16A having a
bridged
configuration to support a pressure tube.
[00321 Figure 17 shows an example of a flat, or planar bracket that could
be used in
accordance with a sump pump assembly described herein.
[00331 Figure 18 shows an example of a pressure tube housing used in
accordance with
examples of sump pump systems described herein.
[00341 Figure 19A shows an example of a sump pump system utilizing check
valves for
demonstrative purposes.
[00351 Figure 19B shows an example of a sump pump system without check
valves for
demonstrative purposes.
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[0036] Figure 20 shows an example of a sump pump assembly utilizing
separate check
valves for each pump in accordance with examples described herein.
[0037] Figure 21 shows an example of a dual sump pump system with an
isolation valve
in accordance with aspects described herein.
[0038] Figures 22A and 22B show a cross section of an isolation check valve
in various
states of operation in accordance with examples described herein.
[0039] Figure 23 shows a cross section of one example of an isolation valve
described
herein.
[0040] Figures 24A shows another example of an isolation valve, and Figures
24B-D
show cross sections of the isolation valve of Figure 24A in various states of
operation
accordance with other examples described herein.
[0041] Figure 25A shows an example of a sump pump system with a redundant
high
water switch in accordance with aspects described herein.
[0042] Figure 25B shows the sump pump system of Figure 25A, with a cover of
the high
water switch removed to show the internal components of the high water switch.
[0043] Figure 26 shows a configuration of a dual pump assembly
incorporating a strap
handle in addition to other features described in the examples presented
herein.
[0044] Figure 27A shows a dual pump assembly with an air switch and a one-
piece
discharge pipe in accordance with examples described herein. Figure 27B shows
a bracket of
the dual pump assembly of Figure 27A in more detail and separate from the
assembly.
[0045] Figure 28 shows a remote display panel for a pumping system that
provides
system status and water level information in accordance with examples
described herein.
[0046] Figure 29A is a top view of an integrated pump controller and
battery
management system in accordance with examples described herein.
[0047] Figure 29B is a rear view of the integrated pump controller and
battery
management system of Figure 29A.
[0048] Figures 30A and B show an example of a tilt switch utilizing an
accelerometer in
accordance with examples described in this application.
[0049] Figure 31 shows an example pumping system employing a sump pump and
the
tilt switch of Figures 30A and B.
[0050] Figures 32A and 32B show various views of an integrated pump
controller and
battery management system in accordance with examples described herein.
[0051] Figure 33 shows a multi-pump system having a connector for
connecting two
pumps in accordance with examples described herein.
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[0052] Figure 34A shows a simplified network diagram over which a pump
communicates in a first state.
[0053] Figure 34B shows a simplified network diagram over which a pump
communicates in a second state.
[0054] Figure 35A is an exemplary flow chart illustrating setup or
installation of the
pump communication system of Figures. 34A-34B.
[0055] Figure 35B is an exemplary flow chart illustrating operation of the
pump
communication system of Figures. 34A-34B after setup.
[0056] Figures 36A-36Q are screenshots of a software application interface
for operating
and/or communicating with a pump system described herein, with Figures 36A-36F
relating
to initial installation or setup of the system by a professional installer,
Figures 36G-36H
relating to setup and registration by a home owner, Figures 36I-36K relating
to normal
operation of the system with a Wi-Fi internet connection present, Figures 36L-
360 relating to
operation of the system when Wi-Fi internet connection is lost, Figure 36P
relating to a notice
provided when regular Wi-Fi internet is available while in Soft AP direct
connection mode
and Figure 36Q illustrating an example of what the screen display would look
like if regular
Wi-Fi internet is available but the AC pump went offline for some reason.
[0057] Figure 37A illustrates a pump system having a wireless communication
module
and a remote display.
[0058] Figure 37B illustrates the wireless communication module of the pump
system of
Figure 37A.
[0059] Corresponding reference characters in the attached drawings indicate
corresponding components throughout the several views of the drawings. In
addition,
elements in the figures are illustrated for simplicity and clarity and have
not necessarily been
drawn to scale. For example, the dimensions of some of the elements in the
figures may be
exaggerated relative to other elements to help to improve understanding of
various
embodiments. Also, common but well-understood elements that are useful or
necessary in a
commercially feasible embodiment are often not depicted or described in order
to facilitate a
less obstructed view of the illustrated elements and a more concise
disclosure.
DETAILED DESCRIPTION
[0060] Sump pumps are often most useful during storms. That is because
storms bring
in large amounts of water that can lead to flooding. However, storms can also
result in a home
losing power. In such a situation, an AC powered sump pump will be unable to
operate.
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Accordingly, for security purposes, home owners also install a battery back-up
system that
can supply power to a DC pump to remove water from the sump basin in the event
of an AC
power outage or primary pump malfunction.
[0061] Such a battery back-up system may include a DC powered pump to
remove water
from the sump basin, float level switches and related components to turn the
pump on & off
based on water levels, and a 12-volt DC battery with a charging system and
related electrical
connections. An example of such a conventional pump 700 is shown in Figure 7.
[0062] Combining a primary AC powered sump pump system with a separate
backup
DC powered sump pump system can present several drawbacks. For example, as the
complexity of these primary & back-up pump systems increase, the overall
reliability can be
impacted by the number of switches and electrical connections.
[0063] Additionally, the ability of the system to transmit messages during
power outages
can be compromised or limited in function, as the notification systems
generally rely on home
functionality (e.g., land line circuits) that are also inoperable during power
outages. Thus,
these systems cannot take advantage of the latest communication technologies.
[0064] Further, sump systems with two pumps and multiple float switches are
often too
large to fit into the smaller diameter sump pits found in older homes. As a
result, such homes
with smaller sump pits are not able to take advantage of the benefits of a
conventional backup
DC sump pump system or require homeowners to purchase items to help place the
pumps in
a staggered manner in the sump pit which is not convenient.
[0065] The present disclosure describes sump pumps that integrate a backup
DC
powered sump pump system into a primary AC powered sump pump. The present
disclosure
also describes sump pumps that integrate control and notification systems that
determine
when to activate the backup DC powered sump pump system, and notify home
owners
regarding the operating status of the integrated pumping system. Still
further, the present
disclosure also describes a redundant pump communication system that allows a
home owner
or pump user to continue to have communication with a pump even when the
primary means
of communication is not available (e.g., such as when a storm knocks out power
to a home
disrupting its network operations). For example, a pump communication system
is disclosed
that utilizes a remote electronic device's own wireless access point
technology to form a
hotspot that the pump communication module can tether to so that the pump is
capable of
communicating even if the primary communication circuit (e.g., a wireless
network circuit) is
down due to a problem with the primary communication network or its components
(e.g.,
router, modem, etc.). In this way, the system forms a secondary or redundant
communication
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technique for the pump to use to maintain communication while the primary
communication
technique is unavailable.
[00661 Figure 1A shows an isometric view of an example tandem sump pump
assembly
100. As shown in the Figure, the sump pump assembly 100 includes a first pump
120 and a
second pump 130. Figures 1B-G show front, rear, right, left, top, and bottom
views of the
tandem pump assembly 100, respectively.
[00671 In the form shown, the first pump 120 is a primary pump powered via
an AC
power supply 102 and the second pump 130 is a backup pump powered by a DC
power
supply 104, such as a battery. However, it should be understood that in
alternate
embodiments the pumps can be setup in any desired configuration. For example,
in some
embodiments, pump 130 could be the primary AC pump and pump 120 could be the
backup
DC pump. In other embodiments, both pumps 120 and 130 could be AC pumps
powered via
an AC power supply, or DC pumps powered by a DC power supply. In still other
embodiments, pumps 120, 130 could be any combination of AC/DC pumps desired.
[00681 Turning back to the embodiment illustrated in Figures 1A-G, in a
preferred form,
the system 100 includes two separate check valves 161 and 162 that inhibit
backflow into each
of the separate pumps, but that ultimately discharge into a common discharge
outlet 160. In
addition, the pump assembly comprises a twin volute 110, that serves as the
volute for both
pumps 120, 130 of the assembly. In some examples, the twin volute 110
comprises two
separate volutes 111 and 112 (e.g., one for each pump) that are not in fluid
communication
with one another as shown in Figure 1G. In some examples, the twin volutes 111
and 112 can
be arranged in a space saving and attached configuration as shown in Figure
1G. In this form,
the volutes 111, 112 are shown to have a "yin-yang" configuration (or semi-yin-
yang
configuration), which allows the pump to save space. This space saving
configuration allows
the assembly 100 to fit into smaller sump pits. In some examples the volutes
111 and 112 may
be similar or even identical in size. In other examples, one volute (e.g.,
volute 112) may be
larger or even significantly larger than the other as will be discussed
further below regarding
alternate embodiments.
[00691 While the embodiment shown in Figures 1A-G illustrate the volutes
being
connected to one another to make the tandem system 100 easier to place in the
sump pit
together as a stable assembly, it should be understood that in alternate
embodiments the
pumps and pump components may be configured so as not to be connected to one
another
except by the common discharge piping to simplify servicing so that one pump
may be
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removed and worked on or replaced without requiring removal of the other pump,
if desired
(which will also be discussed further below regarding alternate embodiments).
[0070] Turning back to the embodiment illustrated, Figure 1G shows the twin
volute 110
as two separate volutes 111 and 112 that are separable from one another, but
interconnected
or connected to one another via a fastener or connector. That is, they are not
formed as part of
a single piece, but are instead held together by way of a fastener or
connector. In alternate
forms, the volutes may be held together with assembly 100 via attachment to
the pump
assembly 100 (e.g., via attachment to their respective pumps which are then
connected to one
another via the common discharge piping). Pads 115a-f on the bottom surface of
the twin
volute can help support the stability of the system 100. In some embodiments,
however, the
twin volute 110 can be a single piece that may be formed, for example, from a
single molded
or cast material. Figure 6 shows an example of a twin volute 610 formed as a
single component.
[0071] In some examples, the independent volutes 111/611 and 112/612 of the
twin
volute 110/610 are not in fluid communication, even if the volutes are formed
as a single
component, as shown in Figure 6. That is, they are discrete or individual
volute chambers or
fluid passages with no fluid path connecting the two volute chambers or fluid
passages. In
other examples, however, the twin volute 110/610 may include a single or
common volute
chamber or fluid passage such that the volute for each of pumps 120 and 130
are one in the
same or at least in fluid communication with one another.
[0072] Referring again to Figures 1A-G, the assembly 100 includes an
integrated handle
140 that allows for both pumps to be carried together, and lowered into a sump
or a pit in a
basement. This integrated handle 140 allows for easy installation or
simplified out-of-box
drop-in setup. In a preferred form, the handle 140 works together with the
common discharge
piping to interconnect the pumps 120, 130 so that the system can easily be
installed or removed
as one assembly.
[0073] As mentioned above, in a preferred form, the assembly 100 has a
single discharge
outlet 160, such that each of the first pump 120 and the second pump 130 pump
fluid toward
the common discharge outlet 160. The discharge outlet 160 can connect to a
discharge pipe via
a check valve. Because the assembly utilizes one discharge outlet for two
pumping units, the
assembly can be installed in a quicker manner. That is, an installer need only
connect a
discharge pipe to a single outlet, which can save considerable time in the
installation process.
Each pump 120 and 130 can pump fluid toward the discharge outlet 160 through
respective
check valves 161 and 162, which are connected via cross-over piping 165. Thus,
this discharge
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piping helps interconnect the pumps 120, 130 to one another so that they may
be placed as an
interconnected assembly.
[0074] In some aspects, the discharge outlet 160, cross-over piping 165,
and check valves
161 and 162 can be moved higher up above the sump pumps 120 and 130. For
example, some
embodiments may utilize a length of tube or pipe such that check valves 161,
162, and
discharge outlet 160 are raised higher, so that they extend out of the sump
pit. Figures 13A-G
present an example of a tandem sump pump assembly 1300 with cross-over pipe
1365
extended at a height above the sump pumps 1320 and 1330 and above the sump
pit. For
example, discharge outlet 1360 and the two check valves 1361 and 1362 are
elevated far above
the assembly and connected via a crossover 1365 pipe significantly above the
sump pumps
1320 and 1330 when compared with the embodiment of Figures 1A-G. That is, the
cross-over
pipe 1365, the primary pump check valve 1361, and the secondary pump check
valve 1362 are
positioned at a height sufficiently high above the primary 1320 and secondary
pumps 1330 so
that when the tandem sump pump unit 1300 is placed in a sump pit, the primary
pump check
valve 1361, and the secondary pump check valve 1362 are accessible for
maintenance and
repair without having to enter the sump pit or remove the tandem sump pump
unit from the
sump pit. In this manner, an operator can effectively disconnect one pump from
outside the
sump without having to turn the system off, as the check valves will be more
readily within
reach. That is, within reach from outside of the sump pit without having to
enter the pit, or
without having to remove both pumps from the sump pit. One pump can be thus
replaced
and/or repaired while the other pump continues to operate. That is, one pump
can be
disconnected from the system and then pulled up from the sump while the other
pump
continues to operate. In such embodiments, the assembly 1300 may employ
separate or dis-
connectable volutes rather than the common volute 1310 described above.
[0075] Figure 15 provides another example of a tandem sump pump system 1500
that
utilizes two separate discharge lines 1660a and 1660b without a crossover
pipe. That is, the
pump system 1500 includes a first pump 1520 and a second pump 1530 that each
utilize a
separate discharge line 1560a and 1560b, respectively. In this example, unlike
that of Figures
13A-G, no crossover pipe connects the primary check valve 1561 and the
secondary check
valve 1562 to direct the pumped fluid to a common discharge line. Instead,
each pump 1520
and 1530 pumps toward its own discharge outlet. This dual outlet configuration
provides
redundancy advantages in that, if one discharge line becomes clogged or
blocked by debris,
vermin, or the like, the other discharge outlet will remain operational.
Further, employing
separate discharge lines allows the system to omit the individual check
valves, if desired (e.g.,
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primary check valve 1561 and secondary check valve 1562 can be optional). This
can provide
added cost savings and a simplified design. Additionally, using separate
discharge lines as
shown in Figure 15 can reduce system pressure drop, which allows the pumps to
operate at a
higher flow rate. In some examples, the check valves 1562 and 1561 (along with
other
components) can be made from stainless steel. In other examples, the check
valves can be
made from a plastic material or other metals.
[0076] In Figures 1A-G the sump pumps 120 and 130 are generally depicted as
being the
same size. It is contemplated that in some embodiments the sump pumps can be
different in
size, shape, or operation. Figure 14 is a bottom view of an example sump pump
assembly 1400
with such a configuration. That is, the first sump pump volute 1411 (which can
be, for
example, a primary pump, such as an AC powered pump) may be larger than the
second
sump pump volute 1412 (which can be, for example, a backup pump, such as a DC
powered
pump). It should be understood that smaller volutes are typically associated
with smaller
pumps and smaller pump housings. Accordingly, it should be understood that the
assembly
1400 of Figure 14 could include two pumps of different sizes.
[0077] Figure 2A shows an example of a tandem sump pump assembly 200
connected to
a discharge pipe 270 via check valves 261, 262 (262 is not shown, but is
similar in type and
location to check valve 162). Figure 2A shows an expanded view that includes
an integrated
control/power module 280. Figure 2B is an up close view of the tandem sump
pump assembly
of Figure 2A. As shown, a rubber coupling connects the discharge outlet 250 of
the assembly
200 to the discharge pipe 270, and is secured via conventional hose clamps.
This configuration
allows the assembly 200 to be placed in the sump pit and then secured to
existing plumbing
if needed. However, in alternate embodiments, the discharge piping may be
configured in a
variety of different ways (see an exemplary embodiment of this in Fig. 13A
which will be
discussed later).
[0078] As shown in Figure 2A, the system also includes a control/power
system 280. In
some examples the control/power system will be an integrated module, as shown
in the
embodiment of Figure 2A, where the control circuit and power circuit are
included as a part
of the same component. In other forms, the control circuit and power circuit
may be integrated
into a controller further removed from the sump pit area, such as the control
unit 510
illustrated in Figures 5A-B. This integrated design moves the pump motor
switch operation
"out of the water", thereby increasing reliability. That is, because the sump
control system
enclosure can also accommodate the battery charging electronics, the charging
components
are moved away from the harsh environment of the battery box and into an area
more
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convenient for viewing & operation by the home owner. This can be useful, for
example, for
sealed sump units with Radon abatement systems. The lower profile of the pump
embodiment of Figures 1A-G (as compared to the high crossover/easy servicing
embodiment
of Figures 13A-G) may also be more desirable in such sealed sump units because
of the ability
to contain the tandem assembly within the sealed pit.
[0079] In other embodiments, the power controller and the communication
module may
be separate modules, so that either module can be removed, uninstalled,
replaced or otherwise
separately provided from the other module. For example, in Figures 5A-B, a
system is
illustrated having separate control and communication modules. By offering a
separate
modular arrangement, the system can take advantage of improvements in power
and/or
communication technologies, without requiring replacement of the other
power/communication equipment. Moreover, the interchangeability of the power
and
control systems allows the systems to be adapted for different pumps and
equipment that
may operate on different power configurations. For example, with this
configuration the
systems can be adapted to be used with 10 amp pumping systems, or 4 amp
pumping systems,
or other pumping systems having differing operating parameters or employing
various
different electrical configurations. In yet other forms, the system may be
configured with
separate pump control, power control and communications modules so that any of
these
modules may be repaired, replaced or updated without requiring change to the
other
modules.
[0080] Returning to the embodiment of Figures 2A-B, the integrated
control/power
system 280 can include a central control system, (also referred to as a
controller) in electrical
communication with the sump pump system (e.g., systems 100 or 200 of Figures
1A-B and 2A-
B). That is, the controller can be in electrical communication with a primary
sump pump that
is powered by an AC power supply and a backup sump pump that is powered by a
DC power
supply. Via the controller, the control/power system 280 can be configured to
control
operation among the primary sump pump and the backup sump pump. Again, as
mentioned
above, the system could be setup to use two DC pumps or two AC pumps as
desired,
however, in a preferred form, the system will be configured with at least one
DC pump, which
would be needed for power outages as discussed above.
[0081] The control/power system 280 also includes a charging module
configured to
charge the DC power supply and a battery that provides power to the pump
system in the
event of a power outage to the home. The charging module can operate to charge
the battery
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when AC power is on to ensure that the battery is fully charged in the event
of a power outage
or other problem with the AC power source.
[0082] In some forms, the controller can serve as the controller for the
entire sump pump
system. In other forms, different controllers may be used for different
responsibilities or,
alternatively, may be setup in a redundant manner as will be discussed further
below. In still
other forms, other fallback designs may be used to help the system operate at
least in a
minimal capacity even if the controller fails. These will be discussed further
below with
respect to other embodiments.
[0083] Figure 3 is a diagram demonstrating various functionality of an
integrated sump
pump control and battery charging system 300. In some examples, the system 300
is
connected to an AC power source 310 (e.g., a 120V power outlet) and, thus,
includes an AC
input (e.g., a power cord and plug, etc.), a DC power source 320 (e.g., a
battery or battery
hookup), or a combination of both. Fluid level inputs can be supplied by
single or multiple
input mechanisms such as float switches 330, relative displacement (tilt)
switches, pneumatic
pressure switches 340 (e.g., probe tubes) or the like. In the form
illustrated, the auxiliary float
switch 330 is meant to connect to a high water float switch or water level
sensor to identify a
high water or flood condition via display 355. In this way, the auxiliary
float switch 330 serves
as a redundant fluid level sensor to back up the pneumatic pressure tube
sensor 340. The
system 300 can also include an audible alarm 360 that can be used to produce a
signal or
warning. For example, audible alarm 360 may include a speaker arrangement, a
buzzer, a
siren, a beeping device, or the like. In some forms, the controller or system
300 further
includes an output to connect to a home security system to trigger an alarm or
notification
condition via the home security system.
[0084] In some forms, the system 300 may include an interface 350 that
displays
information pertaining to the operating status of the system. For example, the
interface 350
may display information pertaining to the water level 351, the battery status
352, and the
operation status of the backup pump 353 or main pump 354. The interface 350
may also
include high water warning icons 355, battery fault icons 356, or control
switches that execute
functionality, like a system test switch 357 (e.g., that activates a system
test protocol) and a
buzzer switch 358 (e.g., that shuts off or mutes a buzzer). In the form
illustrated, the visual
displays 351, 355, 353, 356 and 354 coincide with the inputs 340, 330, 370,
320 and 380,
respectively, and utilize colors to relay information regarding system status
or water status.
For example, green colors appearing in conjunction with the water level sensor
351, back-up
pump indicator 353, battery indicator 356, and main pump indicator 354
indicate the system
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is running properly. Conversely, red colors appearing in conjunction with
water level sensor
351, high water indicator 355 and battery fault and state indicator 356
indicate a potential or
current problem with the system (e.g., low battery, no battery, etc.) or
undesirable high water
level situation. In the form illustrated, the system 300 is setup modularly so
that system 300
serves as the pump controller and nearby notification module, but is also
connected to a
communications or remote notification module to provide further notification
to remote
locations such as remote user locations via an analog or digital auto dialer
unit, a cellular or
digital notification unit, etc. Figure 3 depicts some exemplary data that may
be communicated
between the communications module and system or controller 300 such as AC
system power
status, water level, alarm conditions, DC system power status, battery state,
pump operation,
pump cycle count, system failures and remote diagnostic or testing features.
[0085] Some examples described herein may employ a controller that monitors
and
assesses battery state of health, and/or battery state of charge properties.
Conventional
battery test methods for pumping devices often involve discharging, or at
least partially
discharging the battery. But this can cause problems, in particular, with how
power or heat
generated during the test is dissipated. Accordingly, certain aspects
described herein may
employ battery testing and assessment techniques that use conductance
measurements. Conductance describes the ability of a battery to conduct
current. At low
frequencies, the conductance of a battery is an indicator of battery state-of-
health showing a
linear correlation with a battery's timed-discharge capacity. Accordingly,
information
obtained from the conductance test can be used as a predictor of battery end-
of-life. In one
aspect, a controller may be equipped to utilize similar operating software
that is used to test
equipment related to other industries, such as automotive equipment, and may
also use
advanced monitoring systems that are associated with stationary power
applications. That is,
the testing algorithms used to monitor these other types of equipment could be
incorporated
into a control board of the controller. In this manner, the present controller
can use
conductance testing of the battery to determine state of health and/or state
of charge, which
has not been utilized in conventional battery back-up sump systems.
[0086] The present disclosure also describes warning and communication
systems used
in connection with pump systems. Figures 5A-B show examples of a warning
notification and
communication system. Figure 5A shows an expanded view that includes a system
controller
such as notification module 510 and a communication module 520, and Figure 5B
shows a
close up view of the notification module 510. As shown, the notification
module 510 comprises
a series of LED lights 512n that light up to indicate warnings or other
information. For
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example, the LED lights 512 can represent operation of the backup pump,
operation of the
primary pump, a water level warning, a low battery level warning, a battery
fault warning,
etc. In some examples, the LEDs 512 can include a plurality of lights that
sequentially light up
to indicate an amount of water or fluid in the sump pit. For example, the LEDs
512 can
illuminate in a way to indicate a "low" "medium" and "high" water level so
that a quick
glance at the display immediately indicates the amount of water in the sump
pit (e.g., fewer
illuminated LEDs means low fluid level, intermediate number of illuminated
LEDs means
higher fluid level, many illuminated LEDs means high fluid level, all on and
strobing to
indicate too high of a fluid level or too high of a level for too long of a
period of time, etc.).
The notification module 510 can also be equipped with a speaker or other
audible equipment
to generate sounds or audible alarms in certain situations. For example, the
notification
module can be configured to sound a buzzer or alarm when the water level is
rising beyond
a predetermined threshold or when the fluid level remains at or above a
threshold level for
too long a period of time, etc.
[00871 The communication module 520 can be configured to communicate
notifications
via a number of wireless or wired technologies. For example, the communication
module 520
can be configured to send text alerts via a cellular network. Additionally
and/or alternatively,
the communication module can be configured to send signals via a network, such
as the
internet, via a hard wired or a Wi-Fi connection, a land-line connection, or
another approach.
In this manner, the communication module 520 can communicate and/or interact
with a
remote device, such as a smart phone, a tablet, a laptop or other computer.
[00881 In some embodiments, the module 280 could allow battery back-up to
power the
communication module 520 and other modules or components (e.g., an electronics
module)
during an AC power outage so that notifications, the application services
described herein,
and other features (e.g. cellular or digital notifications, such as text
notifications, etc.) remain
functional and/or operational.
[00891 Figure 8 is a schematic diagram of an example control system 800 for
any of the
tandem sump pump systems described herein. The control system 800 (which can
be the same
as or similar to battery charging and control system 300 described above with
respect to Figure
3) includes a controller, such as microprocessor 810, in connection with a
variety of
equipment, sensors, and outputs. The system 800 includes an AC pump 820
represented by a
motor symbol, which connects to an AC power supply 822 (e.g., a 110 V AC power
supply)
and can be used to operate one pump of a tandem sump pump system.
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[0090] A current sensor 824 monitors the current drawn by the AC pump 820,
and
communicates with the microprocessor 810. In this manner, when current drawn
by the pump
820 (e.g., by the pump motor) is above or below a threshold (e.g., signifying
that the pump
may be having issues), the microprocessor can take any of a number of pre-
prescribed actions.
For example, detection of low current usage may indicate the pump has no more
water to
remove and, thus, the controller may shut down the pump to avoid motor
burnout. Detection
of high current usage may indicate the pump is jammed and, thus, the
controller may cycle
the pump motor on and off to try and dislodge whatever is causing the bind or
may shutoff
the motor and trigger a notification of an error. The microprocessor may
operate any of the
number of outputs, such as the audio alarm 870, LED lights 880, or other
functionality (such
as sending a communication via the communication module) to indicate or relay
such errors.
[0091] In a preferred form, the system 800 will be configured with a first
switch for
operating the primary pump and a second switch for operating the backup pump.
For
example, switch 826 can be used to control the supply of AC power to the
system 800. In some
examples, switch 826 can include any AC switch, such as a solid state relay
(SSR) (e.g., an
opto-triac or triac and alternistor, etc.). In the form illustrated, the
switch 826 is an opto-triac
coupler, which can be employed to block high voltage and voltage transients
from the AC
portion of the circuitry to other areas of the system 800, such as the DC
portions of the
circuitry. In this manner, the switch can help assure that a surge in the AC
part of the system
800 will not disrupt or destroy the other parts of the system 800. In other
examples, the switch
826 can include a DC switch if the circuit includes a transformer (e.g., an
isolation transformer)
and the pump being operated is instead a DC pump.
[0092] Returning back to Figure 8, the system 800 also includes a DC pump
830 (again
represented by a DC motor symbol) which can be used to operate a second pump
of the
tandem pump system. The DC pump 830 receives DC power from either a DC battery
834
(e.g., a 12 V battery), a battery charger 832 (e.g., a 12 V battery charger),
or a combination
thereof. For example, the system may be setup to cycle usage of the pumps
between the first
and second pump 820, 830 so that one does not wear out before the other. Thus,
when the DC
pump 830 is to be used, the battery charger 832 may simply be used as an AC-DC
power
adaptor to step the AC power supply down to DC power to operate the DC pump
830 without
requiring power to be supplied by battery 834 so that the battery remains
fully charged for
use during AC power outage situations. The battery charger 832 is in
communication with
the AC power supply 822 and the battery 834, thereby ensuring that the battery
834 maintains
a charge in the event of an AC power outage. The DC portion of the circuit
also includes a
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current sensor 838 that monitors current drawn by the DC pump 830, and a
switch 839 that
opens and/or closes the DC portion of the circuit. In this manner, the switch
839 can control
the supply of DC power to the DC pump 830 and the controller 800 can perform
similar tasks
to those discussed above with respect to the AC motor when detecting too
little or too much
current draw (e.g., shut off the pump if too little current is drawn
indicating insufficient fluid
presence, cycle on and off the pump to attempt to dislodge a blockage leading
to too much
current being drawn by the motor, turning off the motor if too much current is
drawn by the
DC motor, etc.).
[0093] The system 800 also includes a voltage supply 836 that supplies
power from the
DC battery 834 to the microprocessor 810 or as mentioned alternatively above
from the battery
charger 832 serving as an AC-DC adapter. With this configuration, the
microprocessor 810
can still operate in the event of an AC power outage by drawing power from
battery 834.
Another current sensor 842 monitors the current drawn by the battery 834 to
indicate to the
controller 810 if a problem has occurred with the battery 834 (e.g., too low
or high of a current
being provided, etc.). In other aspects current sensors can be associated with
other
components of the system (e.g., the microprocessor 810) to monitor the current
that the
components are drawing and further notifying of other problems or errors in
circuit or
component operation.
[0094] The system 800 includes a push-button 840, which can be pressed, for
example,
by a user to activate one of a number of system tests. For example, the push-
button 840 can be
pressed to determine whether the battery 834 is sufficiently charged. The push-
button 840 can
also be used for one or more other functions, including, for example, to
silence an alarm,
deactivate a notification, re-set warning signals, start a test cycle, or the
like.
[0095] The microprocessor 810 also operates in connection with a number of
outputs. For
example, the microprocessor 810 may communicate data and/or information via a
data
output 850. The data output 850 can include, a communication device that
transmits text
alerts, notifications, or other communications to a user via a remote device.
[0096] In some embodiments, the microprocessor may also include an
auxiliary signal
output 860, which can be another auxiliary alarm, such as a home security
system and/or a
communication/texting protocol system. The auxiliary signal output 860 can
include a switch
862 that allows the auxiliary output 860 to be activated or deactivated as
appropriate.
[0097] The microprocessor 810 can communicate with an audio alarm 870 that
activates
an audio signal in response to certain events, or a series of lights 880
(e.g., LEDs) that can
execute various lighting sequences in response to certain events as described
herein.
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[0098] In some embodiments the microprocessor 810 is also in communication
with a
number of additional switches and sensors, including, for example, a float
sensor 890, and a
pressure sensor 895.
[0099] The system of Figure 8 demonstrates various examples of redundancy
and/or
backup to ensure proper operation of the system in the event of failure of
some of the
components. For example, the system 800 includes redundant pumps 820 and 830,
redundant
battery sensors 836 and 842 for determining battery performance, redundant
power supplies
822, 834, and redundant water level sensors 895, 890. Figure 8 does not
provide examples of
controller and/or microprocessor redundancy. However, some examples described
herein
provide systems and/or methods to provide redundancy for a controller such
that the system
can continue to function in the event that the controller itself fails. This
controller redundancy
can be provided in a variety of different levels, including a dual processor
level that ensures
full operation of many or even all of the functionality of the system even
when a primary
controller fails. Alternatively, simpler or less expensive systems can also be
provided that
ensure operation of the pumps in the event of a controller failure, but
without providing all
of the other premium features of a more expensive dual processor system.
[00100] Figures 9-12 present examples of pumps and related systems that
offer
redundancy. For example, some systems include two pumps operated, managed, or
otherwise
controlled by a dual processor (e.g., a dual microprocessor). The dual
processor can be
configured so that one portion of the processor operates a first pump (e.g., a
primary pump
or an A/C powered pump) while a second portion of the processor operates a
second pump
(e.g., a backup pump or a D/C powered pump). In the event that one processor
or processor
portion goes down, the dual processor system can configure control so that the
other
operating processor assumes control of both pumps. In this manner, the system
can continue
to operate on all levels even in the event of a failure to one processor. In
some examples, the
dual processor can be, or can include two separate processors, with each
processor portion
comprising a separate processor device. In other examples, the dual processor
is one chip or
board configured to operate as a dual processor.
[001011 Figure 9 is a schematic diagram of a redundant control system 900
for a dual sump
pump arrangement utilizing dual controllers, such as processors 910 and 911.
In this
embodiment, a first microprocessor 910 can be configured to control operation
of a first pump,
for example, an AC powered pump 920. The second microprocessor 911 can be
configured to
control a second pump, for example, a DC powered pump 930. Each microprocessor
can be in
communication with various sensors, and other audio/video alarms or
functionality.
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Moreover, in the event that one microprocessor fails, the other microprocessor
can assume the
functionality of the first microprocessor. For example, if the first
microprocessor 910 fails, the
second microprocessor 911 can assume control of the primary pump 920, while
also assuming
the control of the signaling and other communication functionality described
herein.
Likewise, in the event that the second microprocessor 911 fails, the first
microprocessor 910
can assume control of a backup sump pump 930, and other related functionality.
Moreover,
the system may utilize redundant water level sensors, such as a pressure
sensor 940 and a
high water float switch 942, each of which is in communication with each of
the two
microprocessors 910 and 911.
[00102] While utilizing a dual processor system such as that described with
respect to
Figure 9, such a system can be more complicated and expensive. Accordingly,
the present
disclosure also describes examples where one processor is a simpler processor
than the other.
For example, one processor may be a scaled down or scaled back version of the
other processor
(e.g., a simplified controller) so that in the event of a failure, the
simplified controller can
perform some, but not all of the functionality of the primary processor. In
this manner the
system may be more cost effective and easier to operate on account of the
simplified controller,
but may still be able to perform the important tasks (e.g., prevent flooding)
in the event of a
primary processor failure so that the system can continue to operate in urgent
situations. In
some forms, the power supply for each of the controllers 910, 911 may be
handled separately
as well in yet another example of redundancy. For example, a separate
transformer or step
down/rectifier circuit may be used to supply power to the first controller 910
and the battery
may be used to supply power to the second controller 911. In other forms,
however, both may
be powered from the same DC power source (e.g., such as the battery charger as
an AC-DC
adapter and, if AC power is not available, from the battery as discussed
above).
[00103] Figure 10 is a schematic of another example control system 1000 for
a tandem
sump pump system with redundant controller features. The control system 1000
includes a
microprocessor 1010 in connection with a variety of equipment, sensors, and
outputs,
including a primary pump 1020 (e.g., an AC pump), and a secondary pump 1030
(e.g., a DC
pump).
[00104] Unlike system 900 of Figure 9 which includes dual controllers
(e.g., processors 910
and 911) that can maintain all or virtually all of the functionality of the
system (e.g., including
the warning, transmission, and monitoring features, etc.) in the event that
one microprocessor
or controller fails, the system of Figure 10 operates on a more efficient
basis in the event that
microprocessor 1010 fails. As such, the system 1000 may be simpler and more
cost effective,
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but still allow the pumps 1020 and 1030 to continue to operate in the event of
a failure while
the primary microprocessor 1010 or controller is being repaired or replaced.
In this manner,
the system 1010 may employ a redundant controller, such as monitor 1001 that
communicates,
or is in communication with many of the system components. The monitor 1001
can be
configured to essentially monitor microprocessor 1010 to ensure that it is
operating effectively.
When it detects that the microprocessor 1010 is not operating effectively, the
monitor 1001 can
assume control of one or both of the primary pump 1020 and backup pump 1030 so
that the
essential pumping operations continue to operate as necessary.
[00105] In some examples, the monitor 1001 can serve as another
microprocessor that
performs some of, but less than all of the functions of the microprocessor
1010. For example,
the monitor 1001 may be able to control between operation of the two pumps
1020 and 1030,
but not perform any of the alarm or communication functionality. In other
aspects, however,
the monitor 1001 performs only a small number of tasks, sufficient to keep the
system 1000
operating efficiently while the microprocessor 1010 undergoes maintenance. For
example, the
monitor 1001 may be a simple logic circuit that includes a logic gate or logic
gates (e.g.,
and/nand logic gates, or the like). Thus, the monitor 1001 allows the system
1000 to operate
minimally, such that only the essential operations are performed while the
other module is
replaced and/or repaired. This control system 1000 provides a less expensive
redundant
system that allows the system to "limp home" in the event of a failure,
thereby performing all
necessary tasks.
[00106] In still further configurations, a very minimal redundant
controller or system may
be used that includes a simple relay switch without software or processors in
the
redundant/backup control. Figure 11A is a schematic drawing of a redundant
control system
1100 for a dual sump pump arrangement utilizing a processor 1110 and a non-
processor or
logic based relay controller 1111. The controller can be a simple switch or a
simple relay,
without any software or logic required to operate same (e.g., a software free
controller). The
microprocessor based controller 1110 and the second or redundant controller
1111 can be
provided in a single enclosure as a control unit 1101 or, as will be discussed
further below, be
modular to allow for one to operate the system while the other is serviced
(e.g., repaired or
replaced). In this manner, the simple relay second controller 1111 can be
wired to assume
management responsibilities for the pumps 1130 and 1120 of the system in the
event that the
primary microprocessor controller 1110 fails or malfunctions. In this manner,
the pumps will
either operate (be "on") or not (be "off') as controlled by the relay
controller 1111, which can
be based on one or more sensors, such as float sensors and/or pressure
sensors. In a preferred
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form, the redundant controller 1111 will be capable of operating both the
primary and
secondary pumps. However, in alternate forms, the redundant controller 1111
may only be
capable of operating one of the pumps (e.g., the secondary pump, but not the
other).
[001071 Figure 11B is a more detailed schematic of a redundant control
system 1100a for a
dual sump pump arrangement utilizing a processor and a dual switch software-
free relay
controller. Here, the simple relay second controller 1111 is shown in more
detail as a dual
redundant switch controller. That is, the second controller comprises a first
redundant switch
1111a that operates the primary, or AC pump 1120, and a second redundant
switch 1111b that
operates the secondary, or DC pump 1130. The redundant switches for the
controller system
are two isolated switches with the outputs tied together and the inputs coming
from two
independent sources. Each switch 1111a and 1111b can take on a variety of
forms. For
example, in some forms, similar switches may be used for both the primary and
backup
pumps. In other forms, an AC switch may utilize components capable of
isolating the DC
portion of the circuit from the AC portion of the circuit (e.g., an opto-triac
switch), while the
DC powered switch may include a simple mechanical switch, an electrical switch
such as a
transistor (e.g., BJTs, FETs, etc.), or the like.
[001081 For each switch 1111a and 1111b, the two inputs relate to the
microprocessor 1110
and the high water float switch 1190. If the microprocessor 1110 fails to
operate properly, the
float switch, when it operates, will turn on the switch output which will
activate the AC switch
1111a (e.g., triac switch) or the DC switch 1111b (e.g., FET) to drive one or
both pumps 1120,
1130. Figure 15 is a sketch showing a simplified circuitry for a switch 1111c
that could be used
in such an embodiment. The switch 1511 includes a motor switch 1103 in circuit
with two
opto-isolators 1121 and 1122. However, it should be understood that the actual
circuitry may
be different for AC switch 1111a and DC switch 1111b.
[001091 Figure 12 is a schematic drawing of a system 1200 that allows two
separate
pumping systems 1220 and 1230 to communicate with one another. For example, in
one form,
the pump systems 1220 and 1230 may communicate with one another when placed
proximate
each other via a communication network 1250, which can be a wired connection
or a wireless
connection (e.g., radio frequency (RF), infrared (IR), Bluetooth (BT),
Bluetooth Low Energy
(BLE), near field communication (NFC), Wi-Fi, etc.). In the form illustrated,
the systems 1220
and 1230 can communicate with one another and transmit operational status to a
remote
display unit 1240, such as a monitor or other display (e.g., a mobile phone,
tablet, PDA,
computer, or other network capable component).
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[00110] The control unit 1201 can be configured to have multiple
commination modes
and/or communication circuits for transmitting notifications based on the
current availability
of power and/or internet connectivity. As shown in FIG. 34A, when the entire
communication network 3400 is working properly, the control unit 1201
communicates via a
wireless communications module 1215 (e.g., a Wi-Fi module, Bluetooth module,
RF module,
etc.), which in turn communicates over the internet via an internet service
provider 1216 to
send notifications to the remote electronic device (e.g., display unit 1240,
such as a mobile
device 1240a or personal computer 1240b). The Wi-Fi communications module 1215
is a
wireless communication circuit communicatively coupled to the control unit
1201. In some
forms, the Wi-Fi communication module communicates with a local gateway, such
as a router
or modem in order to transmit and receive information over the internet.
However, in
instances of power failure it is not uncommon to also lose internet access
along with mains
electricity/line power.
[00111] Turning to FIG. 34B, the control unit 1201 modifies the
communication process or
technique when internet access is lost. More particularly, when the Wi-Fi
Communications
Module 1215 loses contact with the internet service provider a notification is
sent to the control
unit 1201. In some forms, the notification comprises a cessation in responses
received at the
control unit 1201 or Wi-Fi communications module 1215 from the internet
service provider
1216 or the remote display unit 1240. When this lack of internet connection is
detected, the
Wi-Fi Communications Module establishes direct communication with the mobile
device
1240a by broadcasting via Soft AP. The direct communication is short range,
communicating
with the mobile device 1240a only if it is onsite and within range of the
broadcasted Soft AP
signal. The range is limited by the range of the Wi-Fi Communications Module,
such as the
range of a standard Wi-Fi connection (e.g., 0-200 feet and in a preferred form
up to 100 feet).
In alternative forms, other protocols are used, such as Bluetooth, Bluetooth
Low Energy, Near
Field Communication, Radio Frequency, Infrared, or Zigbee. In order to work
during power
failures, the Wi-Fi communications module 1215 is powered by the battery
backup discussed
herein.
[00112] The pump system 1200 includes an actuator, such as button 1214, for
establishing
the direct wireless communication mode (e.g., to put the system in broadcast
Soft AP mode
or direct connection mode). In the form illustrated in Figs. 34A-B, the button
1214 is located
on the pump system 1200, and specifically on pump 1201 itself, however, in a
preferred form,
the button 1214 will be located outside of the sump pit 403 such that it can
be more easily
accessed (e.g., such as on the communication module 1215 in Figs. 34A-B and
37A-B, or 520 in
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Figs. 5A-B; on the remote display 2800 in Figs. 28 and 37A; on the controller
1201 in Figs. 37A-
B, 2900 in Figs. 29A-B, 3120 in Fig. 31, or 3201 in Figs. 32A-B; and/or on the
integrated
controller and remote display 300 in Fig. 3, 441 in Fig. 4A-B, 520 in Figs. 5A-
B). Pressing the
button 1214 allows the system to broadcast in Soft AP mode so as to create a
hotspot that
remote devices can pair to in order to continue to get pump data from the
system even though
the primary wireless network connection has gone down for some reason. In some
forms,
pressing the button only creates a temporary pairing, such that it needs to be
paired again
when the primary wireless network connection goes down or future service
visits.
[00113] While such a button or actuator is provided for configuring the
system in or
putting the system into the broadcasting Soft AP mode or direct connection
mode, in a
preferred embodiment the system will be configured to automatically start in
the Soft AP
mode when initially powered up so that a technician or installer can install
the pump and
confirm it is operating via a downloadable software app without the need to
obtain a network
password from the home or business owner having the pump installed. This
allows the owner
to keep his/her/its network password secret and, thus, does not require the
owner share the
password with others and then rest the network password later to ensure
network security.
Thus, the direct connection or Soft AP mode is useful for both setup & install
of the system,
and for allowing the system to continue to communicate data about the system
with a remote
device while the primary wireless communication network is down. In some
examples, the
direct wireless connection is also used during maintenance and service of the
system. A
technician can directly communicate with the control unit 1201 without needing
the SSID and
password for the primary wireless communication mode. This prevents the owners
of the
pump 1200 from needing to give their secure SSID and password to a technician,
and in doing
so reducing their security.
[00114] FIG. 35A is a flow chart illustrating an exemplary
setup/install/maintenance
process for the pump system 1200. First, in step 3502, the person installing
the system, such
as a technician, downloads the mobile application to their electronic device,
such as a
smartphone. In a preferred form, the application may be used for a plurality
of pump systems
1200, so a technician will only have to download the application once and then
can use it
during each installation job. Thus, if the app has already been installed, the
technician/user
can proceed to the next step. The app will preferably be available at one or
more major app
stores or marketplaces, such as the app stores for iOS and Android OS
platforms (e.g., Apple
App Store, Google Play Store, etc.).
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[001151 Next, in step 3504, the technician installs the pump system 1200.
In a preferred
form, the pump system 1200 includes a display device, such as the remote
display panel 2800
illustrated in FIG. 37A, in addition to the Wi-Fi communications module 1215.
Both the
display panel 2800 and Wi-Fi communications module 1215 are installed higher
than the
pumps 1220 and 1230 so that they can be more easily accessed and/or viewed by
users, such
as the owner or resident of the premises the pump system 1200 is installed in.
FIG. 37A
illustrates the pump system 1200 with the display panel 2800 and Wi-Fi
communications
module 1215 at a raised position, even above system controller 1201.
[001161 After powering on the device in step 3506, the system is then
automatically started
in the broadcast soft access point (Soft AP) mode to serve as a hotspot that
the technician can
connect his/her remote device to in order to finish installation. If for some
reason the system
does not start-up in Soft AP mode or if an error has occurred during the
installation process,
the technician can put the system into the Soft AP mode by pressing the button
1214 on the
Wi-Fi communications module 1215 or by selecting the "installer portal" link
on the app as
illustrated in the app screen display of Fig. 36A. FIG. 37B is an expanded
view of the Wi-Fi
communications module 1215 showing the Soft APbutton 1214, a reset button
1217, and one
or more status lights 1218. In a preferred form, depressing the Soft AP button
(referred to as
the LOCAL LINKTM button in FIG. 37B) for a period of five seconds (5s) causes
the WiFi
communications module 1215 to broadcast under Soft AP mode and act as a hot
spot, such
that other Wi-Fi devices, such as the technician's smartphone or tablet, can
form a direct
wireless connection therewith.
[001171 As mentioned above, the technician can alternatively select the
"Installer Portal"
link illustrated in the screen display of FIG. 36A and in step 3508 to place
the system in
broadcasting mode and then select "OK" in the pop-up box of the screen display
illustrated
in FIG. 36B. Once done, the installer can then select the pump hotspot from
the list of available
Wi-Fi networks on the device the technician is using in step 3510. In a
preferred form, the
pump hotspot is illustrated with the name WW-GEM100000XX with the latter
digits being the
pump number. For example, in the exemplary screen display of FIG. 36C, the
pump hotspot
is illustrated as WW-GEM-10000009. Once the installer selects the pump hotspot
from his/her
available Wi-Fi networks, the app should illustrate a scrollable screen like
that illustrated in
FIGS. 36D-F which displays information about the current pump system state.
This allows
the installer or technician to check the status of the pump system as
illustrated in step 3512 of
FIG. 35A and if successful (step 3514), the technician portion of the
installation is complete
and the technician can instruct the owner how to finish setup/registration as
indicated in step
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3518. If the screen display is not displayed successfully as checked in step
3514 (e.g., the app
does not load, a tile of the app indicates something is wrong with one of the
system
components such as the battery is dead, one of the pumps is offline, etc.),
the technician can
reset the system by actuating actuator 1217 (see Fig. 37B) to reset the system
as called for in
step 3516 and restart the Soft AP process as indicated in step 3508.By going
through the direct
connection and the installer portal, the technician does not need to acquire
the account and
password information or the password for the owner's Wi-Fi network.
[00118] As indicated in FIGS. 36D-F, the dashboard illustrated as the
scrollable screen
display of FIGS. 36D-F is comprised of a compilation of "tiles" or boxes that
each relate to a
different system component or function and provide a status or attribute
relating to same.
Thus, as illustrated in FIG. 36D, the top left tile is entitled "AC Power" and
in green the app
identifies that AC power is "ON" within the tile. Similarly, under the second
tile entitled
"Battery Health" the system indicates battery health is "GOOD". The third tile
entitled
"Hours of Protection" provides a battery symbol colored in green to indicate
how well the
battery is charged and estimates how long it will last for if called into
action. In a preferred
form, the battery symbol and text will indicate a combination of the data from
the remote
display unit 2800 illustrated in FIG. 28 which indicates if four possible
states (e.g., battery
health is: good, ok, poor or needs to be replaced; and hours of protection is:
greater than 4
hours, 2-4 hours, 1-2 hours or greater than 1 only). The battery image will
show varying states
of fill and can change from green to other colors reflective of the charge
(e.g., green for good
charge, yellow for ok charge, and red for poor and replace. In other forms,
the battery may
remain green, but show varying stages of filled in green area to indicate
battery life (e.g., all
green for fully charged, three quarters green for ok charge, two quarters
green for poor and
one quarter green for needs replace or recharge). In a preferred form, the
system will use a 75
amp-hour absorbed glass mat (AGM) battery, but can also use deep cycle marine
batteries if
preferred. The battery case that the battery is kept in can be designed for
varying sizes of
battery, but preferably will fit up to a 31-frame size battery.
[00119] In a preferred form, the scrollable screen display of FIGS. 36D-F
will also have
additional tiles indicating if the AC primary pump is ready, if the DC pump is
ready and what
the current water level is in the sump. In the form shown, the app is also
configured to
provide buttons for requesting to "RUN SYSTEM TEST" and/or "MUTE ALARM". If a
run
system test is selected, the system will check the batter to determine its
state of health (SOH),
run the primary pump for a predetermined period of time (e.g., seven seconds
(7s)), and then,
after a short pause, run the back-up for a predetermined period of time (e.g.,
seven seconds
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(7s)). If the mute alarm actuator is actuated, the audible alarm will be muted
for a
predetermined period of time. In a preferred time, the owner can press the
mute button once
to mute the alarm for one hour, twice to mute the system for two hours, three
times to mute
the system for three hours and so on up to eight button pushes/eight hours.
The system test
and mute can be accomplished by selecting these buttons either on the app (see
FIG. 36F) or
on the remote display (see FIG. 28).
[00120] In the form illustrated, the system will remain in Soft AP mode
until changed over
to its primary wireless communication mode, however, in alternate forms the
system may be
configured to time out of Soft AP mode if an available wireless network
connection is detected
or even without if desired. In one form, the Wi-Fi communication module 1215
includes a
timer and stops acting like a hot spot after a predetermined amount of time.
In some forms,
the predetermined amount of time is an amount of time in hot spot mode with no
external
electronic device connected. Once the hot spot mode is terminated, the Wi-Fi
communication
module 1215 attempts to re-establish connection to any stored networks, such
as to the local
wireless router.
[00121] FIG. 35B illustrates an exemplary flow chart process 3550 by which
the
homeowner or resident finishes installation of the pump system and/or uses the
pump system
1200 after installation. As in the process 3500, first the homeowner installs
the software
application on a desired electronic device in step 3552. When the application
is opened a sign-
in screen is displayed, see FIG. 36G. If the homeowner already has an account
and password,
it can be entered on this screen using the input device of the owner's
electronic device, such
as the touch screen on a smartphone or tablet. If not, the user selects sign-
up on the screen of
FIG. 36G to access the sign-up page of FIG. 36H and create an account and
register the pump
system. Once an account is created, the user will only see the sign-in page of
FIG. 36G and no
longer will see the sign-up page of FIG. 36H.
[00122] At the sign-up/registration page of FIG. 36H, the homeowner
registers an account
in step 3554 by entering information into the displayed form, see FIG. 36H.
After registering
an account, the user establish a wireless communication for the pump by
selecting the
preferred wireless network and entering any necessary password for same in
step 3556. After
a wireless network is established, the owner will see the scrollable app
screen display of FIGS.
36I-K which provides information similar to that discussed above with respect
to screen
display FIGS. 36D-F to check provided status of pump systems in step 3558. .
If not already
apparent, FIGS. 36I-K are meant to collectively display all the content on the
scrollable screen
display and thus illustrate overlapping repetitive portions of the screen
display (this is true
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for FIGS. 36D-F as well). In some forms, the homeowner's initial setup will
use the direct
connection technique mentioned above until the wireless password or other
required
information is entered. Once entered, however, the system will communicate via
the primary
wireless connection and only use the direct connection communication (or the
secondary
wireless communication method) if the primary wireless communication method is
not
available.
[00123] If the primary wireless communication connection is lost (as is
checked in step
3560), the application displays the fault screen, see FIG. 36L. The fault
screen notifies the user
that the pump system 1200 is offline, and provides a link to establish a
secondary wireless
communication method, e.g., the direct connection or Soft AP connection
discussed above (see
the link entitled LOCAL LINKTM in offline banner on upper right of screen
display). When
this occurs, the status boxes on the screen or tiles are faded or greyed out
to convey to the
viewer that they are not being updated and reflect the last known data for
each field/tile prior
to the primary communication network becoming unavailable.
[00124] As with the technician installation discussion above, the pump
owner will be
prompted to establish a direct connection via the secondary wireless
communication method
(e.g., the direct connection or Soft AP mode) beginning with the pop-up window
of FIG. 36M
in step 3562. Once selected, the user is prompted in step 3564 to hold the
direct connection
button 1214 (see FIG. 37B) in for five seconds (5s) (or actuate it for 5s) to
place the pump
communication module in the Soft AP broadcasting mode to establish a direct
connection
with the owner's electronic device as illustrated in screen shot FIG. 36N.
Once done, the
owner must select the pump system hotspot from the list of available wireless
networks
displayed on the user's electronic device as illustrated in FIG. 360 and
indicated in step 3566.
Again, in the form illustrated, the pump system hotspot is identified as WW-
GEM-10000009.
Once selected, the owner will see pump system status data similar to what is
shown in FIGS.
36I-K and as specified in step 3568. If the primary wireless network is not
available due to a
power outage (meaning loss of line power or mains power), the initial screen
may be modified
to list the AC Pump tile as "OFF" and list the AC Primary Pump tile as
"OFFLINE" due to no
line power being available as illustrated in screen display or shot FIG. 36Q.
In the exemplary
embodiment of FIG. 36Q, the battery health and hours of protection tiles have
also been
altered to show what the app may display (at any time) if the battery health
is poor or if the
battery has only one hour or slightly more of battery life left just to give
an exemplary
illustration of same. In a preferred form, these battery life and hours of
protection tiles will
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be the same as those shown in FIG. 361 meaning that the battery is fully
charged and in good
health even if the AC pump is OFF/OFFLINE.
[00125] If the primary wireless communication network becomes available
again while
the direct connection is established (as is checked in step 3570 of FIG. 35B),
the system prompts
the user by asking if he/she wishes to terminate the direct connection and go
back to the
primary wireless connection as illustrated in step 3572 and FIG. 36P. If the
user selects leave
the direct connection (called LOCAL LINKTM in FIG. 36P), the system will drop
the direct
connection and reconnect to the primary wireless network connection and begin
checking the
status of the pump system as done in step 3558 of FIG. 35B. If the user elects
to stay connected
under the secondary communication connection (i.e., the direct connection),
the system will
continue to check the status of the pump system as done in step 3568. In the
form illustrated,
the system refreshes its status data much quicker under the primary
communication
connection than it does under the secondary communication connection (e.g.,
primary
communication connection refreshes almost instantaneously (microseconds or
milliseconds)
versus the secondary communication connections much slower refresh rate of
three or more
seconds). In addition, in some systems, the user may not be able to utilize
his/her electronic
device for other uses while it is under the secondary communication connection
(e.g., the user
will not be able to utilize other available wireless networks such as other Wi-
Fi networks, 4G
or LTE or may have limited usage of other networks or features on the user's
electronic device
such as limits on broadband cellular networks and data or apps that would
otherwise be
usable on the user's device). Thus, it is contemplated that most users will
opt out of the
secondary communication connection/direct connection in favor of the primary
communication connection. As mentioned above, the system may also be
configured to
connect the user out of the direct connection or secondary communication
connection after a
predetermined period of time has been detected. In yet other embodiments, the
system may
be configured to do this automatically without prompting the user in the
manner shown in
FIG. 36P and step 3572 if desired.
[00126] The system 1200 can include a control unit 1201, which can be
provided as a part
of the system 1200, or as an independent, or replaceable component. The
control unit 1201 can
include a backup battery 1234, and two control modules 1210 and 1211.
Alternatively, the two
control modules 1210 and 1211 can be independent components that are
installable separately
with respect to respective pump systems 1220 and 1230. Each pump system 1220
and 1230 can
include an AC pump or a DC pump, each of which can be associated with a sensor
such as an
air tube/pressure sensor 1224 or a float switch 1235. Each control module 1210
and 1211 can
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be used to operate the corresponding pumping system, while in turn
communicating via
network 1250 with the other module. The remote display unit 1240 can display
the results of
the communications between the two systems. For instance, the remote display
unit 1240 may
communicate via Bluetooth, 4 wire, other radio frequency transmission or
another similar
technique with the control unit 1201. In this manner, the two systems can be
configured to
operate in tandem, though the systems may have originally been provided or
purchased
independently. For example, with this configuration, the primary or secondary
pump may be
able to take over the operational tasks of the other pump and, in a preferred
form, even operate
the other pump such as when a controller on one pump goes bad or fails.
Ideally, in such a
failed controller situation, the controller that assumes operational control
of the system will
be able to operate both pumps so that the pumps may be cycled on alternately
(or alternately
activated) to prevent one pump from dying before the other due to excessive
use as compared
to the other. Another benefit of having the controllers set up in this manner
is to allow the
controller that has assumed operational control to activate both pumps
simultaneously or at
least together at some point should fluid be rising at a rate that requires
both pumps to operate
in order to keep up with the rate the fluid is rising.
[001271 A benefit to having redundant systems as discussed in the
embodiments above, is
the ability to prevent flooding due to a system or component failure. However,
as mentioned
herein, another benefit to such redundancy is the ability to service one pump
while allowing
the other pump to continue to operate. Furthermore, as mentioned above, an
advantage to
having a redundant controller configuration is the ability to continue to
offer pumping
capabilities when failures occur. As also mentioned, it is desirable to
configure the system so
that a failed component (e.g., pump, controller, etc.) can be removed while
the other
component or remaining components continue to operate or offer pumping
capabilities. As
such, in a preferred form, the controllers may be configured so that separate
circuits or circuit
modules are utilized to allow a controller to be removed and serviced or
replaced while the
other controller remains in place and operational. Similarly, it is desirable
to have all other
modules of the system to offer redundancy and serviceability without
disrupting at least
partial operation of the system. Some preferred systems in accordance with
this disclosure
will also notify a user of any system or component failure or malfunction so
that the systems
or components may be serviced timely.
[001281 The present disclosure presents examples of a sump pump system that
includes a
primary sump pump, which can have an AC power supply, a backup sump pump
having a
DC power supply, and a controller. The controller can be in in electrical
communication with
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the primary sump pump and the backup sump pump, the controller configured to
communicate wirelessly with at least one remote device.
[00129] In some examples, the controller can be configured to control other
systems as a
central control module (e.g., sewage or utility pumps or drainage pumps
located elsewhere
such as outside of home/building).
[00130] In some examples, the controller can be configured to communicate
with other
equipment in a home, such as HVAC equipment, telephone or communication
equipment,
refrigerators, freezers, ice makers washers, dryers, dishwashers, or other
appliances, water
meters, home security systems, or the like.
[00131] The controller can supply output signals to support multiple
notification
technologies (analog, cellular, digital, other). The system could be
configured to send one-way
"push" notifications only or, alternatively, provide two-way communication
(e.g., remote
actuation of pump, diagnostic check, etc.).
[00132] The control components of the system, such as system 300 of Fig. 3,
can be
configured in a variety of ways. For example, they can be combined with the
battery charging
electronics and mounted in a highly visible location in the surrounding area
of the unit (e.g.,
on the basement wall for a sump pit, or on the discharge pipe near the sump
pit, etc.). In some
examples, the system 300 can also include a 12 V DC output 370 and/or an AC
output 380.
These outputs 370, 380 can be used to provide power to other ancillary devices
or equipment,
such as communication devices, signaling equipment, sensors, test equipment,
light sources,
etc.
[00133] The sump control system enclosure can also accommodate the battery
charging
electronics, thereby moving the charging components away from the harsh
environment of
the battery box and into an area more convenient for viewing & operation by
the home owner
(ref. sealed sump units with Radon sensors).
[00134] In some examples, the system includes a pressure switch that, along
with the
controller, can also operate both the first and second (e.g., AC and DC)
pumps, thereby
alleviating the use of multiple float-type switches in the sump pit so that
the system is more
compact and fits into smaller diameter pits found in many older homes.
[00135] In the event of high water intake, the central controller can
operate both AC & DC
(or two A/C) pumps simultaneously to remove a higher volume of water from the
basement.
The central controller could also alternate activation between pumps to
effectively "exercise"
each system to ensure operation and to balance the number of cycles on each
unit.
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[001361 The central control system can supply output signals to support
multiple
notification technologies (analog, cellular, digital, other). The system could
be configured to
send one-way "push" notifications only or, alternatively, provide two-way
communication
(e.g., remote actuation of pump, diagnostic check, etc.).
[001371 The controller can include a communication module and is thus
configured to
communicate wirelessly via a network. For example, the controller can be
configured to
communicate via a Wi-Fi signal or via a cellular network. In some examples,
the controller can
also monitor various events relating to the operation of the sump pump system.
For example,
the controller can be configured to monitor the operating status of the AC
power supply, the
power level of the DC power supply, the operating state of the primary and/or
backup sump
pump, problems during operation of the pump, a cycle count of the primary
and/or backup
pump; an electric current draw rate of the sump pump system, a water level at
or around the
sump pump, and the rate at which the water level is rising or falling in the
sump.
[001381 The controller may be configured to perform diagnostic operations
on at least one
of the primary sump pump and the backup sump pump. The controller can also be
configured
in some examples to monitor and communicate in real-time information relating
to the fluid
level, the battery state, the current usage, and the on/off status of the
equipment of the sump
pump system. In some approaches, the controller includes a communication
module, is
configured to communicate notifications to a remote device, such as a smart
phone, a tablet
computer, or anther computing device. The communications module could be a
separate unit
or integrated into the control enclosures. The controller can be configured to
communicate
notifications at predetermined time intervals, or during predetermined time
periods.
[001391 The controller can be configured to automatically communicate
notifications in
response to the detection of certain events. For example, the controller may
be configured to
communicate notifications relaying information pertaining to a power outage, a
change in the
operation state of the primary and/or backup sump pump (e.g., the backup pump
turns on,
off, or increases/decreases in pumping rate, frequency of operation, cycles,
etc.), the detection
of a battery level of the DC power supply below a predetermined threshold
(e.g., the battery
has less than 50%, 25%, 15%, 10%, or 5% power, etc.), a detected problem in
the operation of
the pump, a detected cycle count of the primary and/or backup pump exceeding a
predetermined threshold (e.g., the pump has performed about 50% of the life
expectancy of
the pump), an electric current draw rate of the primary and/or or backup sump
pump above
a predetermined threshold, a detected water level rising above and/or falling
below a
predetermined threshold, and a detected water level rising and/or falling at a
rate above
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and/or below a predetermined threshold (e.g., water is rising faster than the
pumping system
can pump). In some aspects, the controller is also configured to monitor and
report on the
brush life of the DC pump motor (or any pump motor) by determining the total
"on" time
(i.e., the total time in which the pump has been running) throughout the life
of the pump.
Thus, once the motor has been operated or cycled on for a predetermined amount
of time
associated with a certain percentage of motor brush wear, the system will
provide a notice
(e.g., audible and/or visual alarm, data notification such as text or alert,
audible
communication, etc.). This predetermined amount of wear can be any amount
desired, (such
as 75% wear, 80% wear, 90% wear, 95% wear, 100% wear, etc.), and may include
multiple
notices to increase the likelihood that the motor will be timely serviced
before a failure occurs
(e.g., such as by replacing the motor brushes before they reach or by the time
they reach what
is predicted to be 100% wear).
[00140] Some versions of the controller are configured to communicate
notifications that
offer coupons for new system in response to the controller detecting a life
cycle count has
exceeded a predetermined threshold. For example, when the controller detects
that the pump
has reached the midway point of the life expectancy of the pump (or its life
expectancy), the
controller may send coupons, reminders, or other notifications to alert a
consumer to purchase
a new pump and/or perform service or maintenance on the pump. In some aspects,
the
controller may communicate notifications that offer an extended warranty
option for systems
that the controller has detected a life cycle count that exceeds a
predetermined threshold (e.g.,
indicating that the user may want to pay for such extended coverage given its
system is
detected to be working at usage levels that exceed normal usage guidelines or
thresholds). In
some approaches, the controller is configured to track unit parameters that
provide insight
into whether a warranty should be honored. For example, the controller can
track whether
warning notifications have been properly addressed and/or ignored by the pump
owner.
That is, the controller may determine that a sump pump system failure is a
result of ignored
notifications communicated by the controller, and use this information to
determine if
warranty status is still authorized.
[00141] In some forms, the controller can receive communication signals
from a remote
device, and perform functionality in response to the communication signals
received from the
remote device. For example, the controller can be configured to receive
signals from a user
operating an application on a remote device (e.g., a smart phone) that
instruct the pump to
turn on, turn off, activate a backup pump, etc. In response the controller
will effect operations
of the pump accordingly (e.g., self-test, self-diagnostics checks, etc.).
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[00142] Some examples described herein also present a mobile application
used in
connection with a sump pump system. The application can be configured to
operate on a
remote device, such as a smart phone, a tablet computer, or the like ("app").
The mobile "app"
may include an interface that can provide information to the user, and can
allow the user to
execute various functionality.
[00143] In some approaches, the app is configured to operate one or more of
a variety of
features. For example, the application can be configured to operate one or
more of the
following features/ functions:
(1) display key system status parameters (water level, battery state, power
on/off);
(2) perform diagnostic check/systems test;
(3) provide real-time fluid level feedback, battery state, current usage,
on/off
state, etc.; (the app can provide active feedback or a closed-loop controller
concept);
(4) track real-time or time lapsed pump usage and prompts notifications at
desired
time periods;
(5) offer coupon for new system once predetermined life cycle count has been
reached;
(6) offers extended warranty option when pump is approaching original warranty
limit; and/or
(7) tracks unit parameters to provide insight on whether warranty should be
honored or not (e.g., if system repeatedly advised user of problems and
failure
was due to user ignoring notifications).
It should be understood that reference to "real-time" as used herein may mean
exactly that,
i.e., real-time data, or it may include slightly time-delayed data that may be
better described
as nearly real-time or not old/historical data.
[00144] The system can be configured to execute/display/operate the same
functions on
a display associated with the unit itself (e.g., a display interface at or
around the controller or
integrated module) that are executed on the app. Some examples described
herein also apply
the use of a pneumatic pressure switch that eliminates and/or reduces the
number of moving
parts, which can result in an increase in system reliability. Figures 4A-B are
sketches showing
an example system 401 that uses a pneumatic pressure switch. The system 401
includes a
sump pump 400 and a pressure tube 440 in a sump pit 403. The sump pump 400 is
connected
to a power source 410 (e.g., a 120 V AV 60 Hz outlet) via a sump pump power
cord 404, and
is configured to pump fluid out of the sump pit 403 through the pump discharge
outlet 460.
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The pressure tube 440 has a pressure tube inlet 447, and is connected to a
switch device 441
via a flexible tubing 442. The switch device 441 can be or can include a
pressure transducer, a
printed circuit board, a microprocessor, a triac switch, or the like. A
piggyback cord 445
supplies electrical power to the switch 441 from the power source 410. The
pneumatic pressure
switch system 401 of Figures 4A and B can be configured to flush air after a
predetermined
period to recalibrate and eliminate problems with condensation build-up or
tube leakage. In
some examples, the pneumatic switch tube 440 could be of a basic plastic
construction, or
wholly or partially constructed from copper to help reduce the build-up of
iron ochre. While
it is known to use capacitive sensors in sump pump systems (see, e.g., U.S.
pat. nos. 8,380,355,
and U.S. app. no. 13/768,899 (Mayleben et. al.), owned by Wayne/Scott Fetzer
Company, both
of which are hereby incorporated by reference in its entirety), such systems
may evoke
additional steps to ensure that the air tube is back to atmospheric pressure.
The present
disclosure describes systems that employ sensors that are adapted to operate
so that the water
level is held below an opening. In this manner the fluid level in the pit
maintains a certain
level with respect to the fluid level in the tube (e.g., the pit and tube
fluid levels do not have
to be equal or level with one another, but rather simply correlate with one
another so that the
level in the tube can be used to calculate a corresponding level of fluid
within the pit). Further,
in some examples, the systems will be configured to turn on after a
predetermined time so
that the air in the tube returns to atmospheric pressure.
[00145] Some examples described herein provide a variety of uses and
functionality. One
embodiment includes a pump volute design that supports close nesting of pumps.
Another
embodiment includes a water level sensing algorithm that receives inputs from
an air tube to
a PCB mounted pressure transducer. Though the air tube can be arranged in a
variety of
configurations, in some aspects the air tube may be arranged in a generally
vertical
orientation. Another embodiment includes the ability to remotely mount the
sensing/ switching electronics out of the sump pit. Some examples described
herein provide
an integrated water level sensing & DC battery charger electronics in one
enclosure. Some
aspects described herein provide a communications module that can receive &
send data from
the central control unit. Some examples include a mobile application that can
receive push
notifications showing system status. Still other examples, offer two-way data
communications
between App & central control to allow remote system test.
[00146] Some examples described herein present a redundant control system
for a
pumping system or pumping arrangement. The pumping arrangement has at least
one pump,
and can include a primary (e.g., an AC) pump and a secondary or backup pump
(e.g., an AC
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backup pump or a DC pump). The redundant control system includes a primary
controller
that directs or manages operation of the at least one pump, and a secondary
controller that
controls operation of the at least one pump in the event that the primary
controller is
inoperable, unavailable, or otherwise non-functional. In some forms the
primary controller
controls operation of the primary pump and the secondary controller controls
operation of
the secondary or backup pump. In some examples, the secondary controller is
configured to
control operation of the first pump in the event that the primary controller
is inoperable.
[001471 The controllers can be either AC powered, DC powered, or both. For
example, the
primary controller may be an AC powered controller and the secondary
controller can be a
DC powered controller, but also be provided with an AC supply that keeps the
DC powered
controller charged. The controllers can take on a variety of forms. For
example, in one aspect,
the primary controller may include or be a primary microprocessor. The
secondary controller
can also be a software executing apparatus, such as another microprocessor, a
logic circuit, or
the like. In certain embodiments the secondary controller can perform all of
the functionality
of the primary microprocessor. However, in other embodiments, the secondary
controller is
limited in functionality, and can only perform some of the duties of the
primary controller.
For example, the secondary controller may only be able to turn on and off the
pumps of the
pumping arrangement. In some aspects, the secondary controller is software-
free utilizing a
relay or a mechanical switch. In some aspects, the secondary controller
includes a monitor
configured to observe operation of the primary controller, and can assume
operation of both
the primary and secondary pumps, if required.
[001481 It should be understood that the presently described pumps,
systems, controllers,
and related equipment can be utilized in a variety of different methods or
processes. That is,
the present disclosure contemplates using the described pumps, systems,
equipment, or the
like in a variety of methods, processes, or techniques that utilize the
advantages of the related
equipment. For example, one method involves reducing the footprint (e.g.,
reducing the
overall occupied space) of a two-pump pumping system. The method includes
connecting a
primary pump check valve and a secondary pump check valve to discharge outlet
with a
cross-over pipe that extends over the primary pump and the secondary pump,
placing the
two-pump pumping system into a sump pit, and connecting the discharge outlet
to create a
redundant system.
[001491 Another method involves activating a pump of a sump pump system.
The method
includes providing a primary controller electrically connected to a primary
pump, whereby
the primary controller has a primary interface for communicating with a
primary and
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secondary pump. The primary interface is operated to activate the primary
pump, a secondary
pump, or both pumps, when the fluid level sensor indicates a predetermined
fluid level has
been reached.
[00150] Another method involves placing a two-pump pumping system into a
sump pit.
The two-pump pumping system includes a first pump having a first volute and a
first
discharge pipe segment, and also includes a second pump having a second volute
and a
second discharge pipe segment. The first and second discharge pipes are
connected to one
another to interconnect the first and second pumps to one another. The two-
pump pumping
system can then be placed into a sump pit as an integrated assembly. In such
configurations,
a check valve would be positioned in line with each pump discharge or in other
forms an
isolation valve like the one discussed further below could be used.
[00151] Yet another method involves pumping fluid from a sump pit with a
two-pump
pumping system. The method includes pumping fluid from the sump pit with the
primary
sump pump, and detecting one or more conditions associated with at the pumps
and/or the
sump pit (e.g., the fluid level in the sump pit). In response to detecting one
or more
predetermined conditions, the secondary pump is then activated to pump fluid
from the sump
pump. For example, when the method detects that water in the sump pit has
exceeded a
predetermined height, the secondary pump can activate to facilitate the
pumping of the
primary pump.
[00152] Other methods relate to the transmission of notifications that
relate to a pumping
system installed in a sump pit. First, one or more pumping conditions
associated with at least
the pumps or the sump pit are detected via one or more sensors. In response to
detecting one
or more conditions (which may be predetermined), a controller will transmit a
signal, for
example, to a remote device. The signal can include information or otherwise
notify a user of
the circumstances associated with the detected conditions.
[00153] As discussed above, some examples of the dual pumping system
include dual
pumps that are integrated via a shared volute or other structural designs that
combine the
volutes of two pumps into a common space. These pump volutes can be
manufactured
together as a single component, or they can be joined via components that
inhibit separation
of the two pumps. For example, the pumps may be cuffed or otherwise connected
via a bracket
or other structure.
[00154] Figure 16A shows an exemplary sump pump assembly 1600 with a
bracket 1610
that cuffs the two pumps together in accordance with examples described
herein. The bracket
1610 is shown removed from the pump assembly in Figure 16B for clarity. In
this example, the
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volutes for each pump have an outlet portion, which may comprise a collar 1630
and 1631
configured to attach to a discharge pipe 1660. The bracket 1610, may comprise
annular
portions 1612 and 1614 configured to surround the collars 1630 and 1631,
respectively, thereby
embracing or "handcuffing" the two pumps together. The brace can take on a
variety of forms
and configurations, but in some forms, the brace will extend between the two
pumps, and will
connect to each pump on opposing sides of the assembly 1600. In Figures 16A
and B, the
bracket 1610 is shown to have a bridge configuration with a raised portion
1635 between the
two annular ends 1612 and 1614. This raised bridge portion 1635 raises up so
as to support a
pneumatic pressure tube 1620 box or housing, which can attach to a tube 1621
via a connector
1622, and function as a sensor to control operations of the pump assembly
1600.
[001551 In other configurations, however, the bracket can have a straight,
flat, or planar
configuration, as shown in Figure 17. In this example, the bracket 1710 has a
dumbbell like
shape, with two end portions 1712 and 1714 separated by a central portion 1730
that is planar
with the ends 1712 and 1714. Such a configuration may provide added strength
and stability
to the assembly, reducing the number of points of weakness that may be present
on a bridge
shaped bracket, particularly in situations where the bridge is not used to
support a pressure
tube.
[001561 As discussed above, some pumping systems described herein include a
pressure
tube that can serve as a sensor to control the pumping of fluid by the system.
The pressure
tube can be installed or installable with respect to the system in a variety
of different
configurations. In Figures 16A and B, the pressure tube 1620 is held in
between the two
pumps, and supported by a bridge shaped bracket 1610. In other configurations,
however, the
pressure tube can be stored within a housing, such as the housing 1820 shown
in Figure 18.
The housing 1820 can be configured to attach to the pump assembly along an
outer periphery
of the assembly. For example, the housing 1820 may include attachment
mechanisms 1825
(such as holes or protrusions) that facilitate attachment to an upper surface
of a volute of a
pump assembly. In some forms, the housing 1820 may have a curved shape and be
configured
to correspond with the contour of the pump assembly to provide a more
streamlined
appearance. The housing 1820 may include an aperture 1822 that may be
configured to hold
and support a pressure tube.
[001571 The present application also describes examples of sump pump
assemblies that
utilize various check valve systems that control the flow of fluid out of the
pump, and inhibit
the flow of fluid back into the pumps. Many systems that utilize multiple
pumps are
configured to discharge both pumps through a common discharge pipe. This
avoids the
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additional cost of routing a second line dedicated to the secondary or backup
pumping unit.
However, when this technique is employed, in particular with centrifugal
pumps, it may be
important to utilize check valves in the discharge lines of one or more of the
pumps (and
preferably both) to block or inhibit flow from one pump back into an inactive
pump unless an
isolation valve like the one discussed below is used.
[00158] Figures 19A and 19B demonstrate why check valves are preferred in
dual pump
systems with a shared discharge pipe. In Figure 19A, the dual pump system
1900, which
utilizes check valves, includes an active pump 1910 and an inactive pump 1912
that both
pump through outlets toward a common discharge pipe 1960. In this system 1900,
the flow
path from each pump toward the discharge pipe 1960 includes a check valve 1961
and 1962.
These check valves allow fluid from the pump to pass out of the pump, but
inhibits fluid from
passing backward into the pump. Thus, in Figure 19A, fluid pumping out of the
pump is
directed out of the discharge pipe, and check valve 1962 stops fluid from
recirculating into the
inactive pipe.
[00159] Figure 19B shows a dual sump pump system 1901 that does not utilize
check
valves. In this system, fluid from the active pump 1910 is pumped toward the
discharge pipe
1960. But because the secondary or backup pump 1912 does not utilize a check
valve, some or
even all of the fluid pumped by the active pipe is recirculated back through
the backup pump
and back into the sump pit. Not only is this system ineffective and
inefficient as the system
essentially is recirculating fluid back into its own system, which can result
in flooding the
surrounding environment and/or be harmful to the inactive pump.
[00160] Certain aspects described herein utilize a system that employs dual
check valves
in the outward flow path of each pump. Figure 20 shows an example of a sump
pump
assembly 200 utilizing separate check valves 2024 and 2025, for in the outward
flow path for
each pump. This situation is similar to the one described in Figure 19A. This
dual check valve
configuration is highly preferred for operation in pumping systems with a
common discharge.
However, in certain situations it may be desirable to reduce the number of
check valves
provided in a system without effecting the end result, such as by using an
isolation valve.
Accordingly, some aspects of this application relate to an isolation valve
(also referred to as a
diverter valve) that can conserve space and cost by providing a single valve
that operates to
the same effect of a dual check valve system. That is, the isolation valve can
effectively allow
each pump to pump fluid toward a common discharge pipe when they are active,
while also
inhibiting or preventing the recirculation of fluid back into an inactive
pump. Such a system
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may be utilized to allow both pumps to pump fluid simultaneously, thereby
allowing the
system to operate in a maximum pumping mode when water levels rise to a
particular level.
[00161] Figures 21-24 show various examples of isolation valves or single
piece discharge
units that can be used in place of a dual check valve system. Figure 21 shows
an example of a
dual sump pump system 21 with an isolation valve 2110 that controls the flow
from each of
two pumps 2120 and 2130 toward a common discharge pipe 2160. This isolation
valve 2110
can be used to stop or inhibit the backflow of fluid through an inactive pump,
while
simplifying the pump system and reducing the overall number of components and
connections required. As shown, the isolation valve 2100 can also serve as a
fork or junction
that combines the two outward flow paths from each pump into a single flow
path, which in
turn flows into the common discharge pipe 2160. The embodiments with a single
flap or
flapper are diverters only and, in preferred forms, will still utilize a
downstream check valve
to ensure fluid does not recirculate. Conversely, the embodiments with two or
dual
flaps/flappers will preferably be sufficient to prevent recirculation of fluid
so that
downstream check valves are not needed.
[00162] Figures 22A and 22B show a cross section of an isolation valve 220
in various states
of operation. The isolation valve 2200 has an inverted U or Y shape,
representing a fork or
junction where two flow paths 2210 and 2220 from two separate pumps join
together. Each
flow path 2210 and 2220 flows through a junction toward an outer flow path
2300 in the valve
2200, which in turn connects to a common discharge pipe 2260. Within the
junction, the valve
2200 includes a flapper 2250 that rotates about a hinge 2252 among a variety
of configurations.
[00163] In one configuration, shown in Figure 22B, the flapper is angled to
the left, thereby
blocking or obstructing the flow path 2210. In this configuration, the flow
path 2220 is clear to
pump fluid toward the discharge outlet 2230 while the other flow path 2210 is
obstructed so
that recirculated or pumped fluid will not flow back toward the pump. In
another
configuration, the flap 2250 may move to the right, thereby allowing flow from
the flow path
2210 while preventing recirculated flow back down path 2220. In still other
configurations,
the flapper 2250 may be positioned in the center, thereby allowing outward
flow from each
flow path 2210 and 2260.
[00164] The flapper 2250 of Figure 22A is shown as a 2-piece configuration,
having a first
flapper part 2254 on the left side configured to obstruct flow path 2210 and a
second flapper
part 2255 on the right side configured to obstruct flow path 2220. When one
flow path is open,
a flow path may flip a flapper part adjacent to the other flapper part. In
preferred forms, this
eliminates the need for having any check valves downstream.
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[001651 The flapper 2250 may be configured to move based solely on the
mechanical forces
of the pumped fluid. For example, the force of water or other fluid pumped by
the pumping
system can push the flapper 2250 to an open position. The flapper 2250 can
include a spring
hinge that defaults the flapper 2250 or both flapper parts 2254 and 2255 to a
closed position
when no fluid is being pumped through the respective flow paths 2210 and 2220.
In some
situations, the flapper 2250 or its components can be mechanically or
electronically controlled
via a system that toggles the flap 2250 between positions. The control system
may
communicate with the pumping system, or may detect that the pumping system is
operating
in a certain way, and thus move the flap 2250 to an appropriate position. This
control feature
may allow the system to determine an ideal flapper 2250 location depending on
the amount
of fluid being pumped from each flow path, and may allow the system to
coordinate optimum
flow rates. This control may also allow the system to execute an override to
move a flapper in
a situation when a particular pump is not operating or not functioning
properly.
[001661 Figure 23 shows a cross section of one example of an isolation
valve 2200. Unlike
the embodiment of Figures 21 and 22, which has an inverted U or Y shaped
configuration that
involves a bend or curve in the outward flow paths from each pump, the
isolation valve 2300
of Figure 23 allows one flow path 2320 to have a straight or linear flow path.
In this
configuration, a first flow path 2310 coming from a first pump angles toward
the discharge
portion 2330 of the valve, thereby joining flow paths with the second linear
flow path 2320.
Because the first flow path 2310 has a bend, the flow resistance may be
increased as compared
to the second linear flow path 2320. As such, the diameter of this pipe may be
increased to
account for the flow rate drop. Alternatively, the diameter may be generally
the same, but the
first flow path 2310 may be configured to attach to a stronger pump, for
example, an AC
powered pump, which may be more equipped to handle pumping through such a flow
path.
In this way, the linear flow path 2320 may offer lower flow resistance to a
weaker pump, for
example, a DC or battery powered pump, or a smaller pump that may be used as a
backup or
secondary pumping source. In this way, the backup pump can be configured to
pump fluid
in a "straight shot" configuration, thereby reducing the flow resistance to a
pump that may
not be equipped to handle as much flow resistance.
[001671 The valve 2300 includes a flapper 2350 that rotates between
positions that enable
flow through the linear flow path 2320 while obstructing recirculated flow
through the curved
flow path 2310, as shown in Figure 23. In another configuration, the flapper
2350 may obstruct
the flow back into the linear flow path as fluid flows out of the curved path
2310. In still other
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configurations, the flapper 2350 may be positioned between the two flow paths,
thereby
enabling outward flow from each path, for example, when both pumps are in
operation.
[00168] This straight shot configuration can be used in connection with a
sump pump
system that has dual pumps, as described in accordance with several of the
embodiments
presented herein. That is, the straight shot configuration may be utilized in
an assembly that
utilizes a primary pump to pump fluid through a primary outlet pipe or flow
path toward a
common outlet pipe, and a secondary or backup pump configured to pump fluid
through a
backup outlet pipe or flow path toward the discharge outlet pipe. The terms
primary and
secondary or backup here are used for identification purposes, and may not
necessarily
represent functional roles of the pumps. For example, in some embodiments both
pumps may
be AC powered pumps that can interchangeably execute "primary" pumping
capabilities. In
other examples, both pumps could be DC powered pumps that interchangeably
execute
primary pumping capabilities, or that are both used redundant backups as a
part of a larger
pumping system.
[00169] This configuration may employ a straight shot feature so that one
of the pumps
can pump fluid through an outlet pipe or flow path that runs generally
parallel with the
discharge outlet pipe, and thus does not experience a substantial pressure
drop or increase in
flow resistance. This straight shot feature may employ the use of an isolation
valve or outlet
flow path unit as shown in Figures 23 or 26. Because this isolation valve
includes one straight
flow path, a second flow path may include a bend or curve, thereby giving rise
to a pressure
drop or potential flow resistance. In some situations, the bend can be gradual
or angled, as
shown in Figures 23 or 26, but in other examples, other configurations may be
used. For
instance, the isolation valve may include a curved flow path that intersects a
discharge outlet
pipe, or an outlet portion of the isolation valve at a right angle. In certain
situations, the
pumping assembly will be configured so that the straight shot feature aligns
with a pump
(e.g., the secondary or backup pump) that has a lower pumping power among the
multiple
pumps. In this way, the weaker or backup pump can pump effectively regardless
of which
pump is operating. In backup outlet pipe is an extension of the discharge
outlet pipe.
[00170] Figures 24A shows another example of an isolation valve 2400.
Figures 24B-D
show cross sections of the isolation valve of Figure 24A in various states of
operation
accordance with other examples described herein. In this configuration, the
isolation valve
2400 has two linear and parallel flow paths 2410 and 2420 that meat at a
junction 2405 to
converge into a single outward flow path 2430. Positioned in the junction 2405
is a flap 2450
that toggles between a positon that blocks flow back into path 2410 (Figure
24C), a position
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that blocks flow back into path 2420 (Figure 24D), and a middle position
(Figure 24B) that
allows flow out of both paths 2410 and 2420. In this dual flow configuration
of Figure 24B, the
configuration of the valve 2400, the junction 2405, and the flap 2450 allows
both flow paths
2410 and 2420 to pump fluid at a relatively high flow rate, without
experiencing substantial
flow resistance and thereby suffering pressure or flow rate drops at the
junction.
[00171] As noted, various forms of these isolation valves can be used in
connection with
a variety of the various pumping systems or assemblies described herein. In
one example, a
sump pump system includes a tandem sump pump unit, which in turn includes a
primary
pump and a secondary pump, each being arranged to pump fluid toward the
discharge outlet.
The system also includes an isolation check valve in fluid communication with
each of the
primary pump, the secondary pump, and the discharge outlet. The isolation
check valve
operates in multiple operating configurations, including a first configuration
where the
isolation check valve permits the flow of fluid from the primary pump to the
discharge outlet
but obstructs the flow of fluid out from or back toward the secondary pump.
This
configuration can involve the use of a flap that pivots to close and seal a
flow path toward the
secondary pump, but leaves the flow path from the primary pump generally
unobstructed.
[00172] The isolation check valve may also operate in a second
configuration wherein the
isolation check valve permits the flow of fluid from the secondary pump to the
discharge
outlet but obstructs the flow of fluid out from or back toward the primary
pump. This can be
achieved, for example, by rotating the flapper unit from the first position
where the flow path
form the secondary pump is cleared, but the flow path back to the primary pump
is obstructed
and sealed.
[00173] The isolation check valve may also operate in a third configuration
that permits
the flow of fluid from both of the primary and secondary pumps in the third
configuration.
This can be achieved, for example, in the configuration shown in Figure 24B,
where a flap is
in a position that permits outward flow from both flow paths. Depending on the
size, shape,
and configuration of the isolation valve, the flow paths, and the flap, this
third configuration
can be arranged so that pressure drop at the junction is minimized or
otherwise arranged to
allow flow from both pumps without a substantial pressure drop or flow
resistance.
[00174] The various configurations of an isolation valve or a diverter
valve as described
herein can provide specific benefits for a multi-pump system over a system
that employs
multiple separate check valves. For example, in a dual pump system with check
valves, the
primary pump (e.g., an AC pump) check valve will typically cycle every time
the primary
pump runs. This repeated cycling on and off can cause wear and fatigue to the
flappers in the
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valves. After time, this wear and fatigue could result in the flapper and/or
the valve failing,
thereby giving rise to potential flooding situations. The presently described
isolation/diverter
valves, however, can inhibit these problems by limiting, inhibiting, delaying,
and/or
preventing the wear and fatigue on the flapper mechanism of the valve. For
example, as
described above, the isolation valve can be configured so that the flapper
moves to block a
flow path when fluid is flowing out of the opposing path. Because a primary
pump may run
far more frequently than a secondary pump, the flapper may be in the same
position (e.g.,
held in place horizontally like a sewer lid either by gravity and/or water
pressure),
continually blocking the secondary flow path even after the primary pump has
cycled on and
off multiple times. In this way, the isolation/diverter valve flapper will not
need to move each
time the primary pump turns on and off; it can simply remain in place. The
isolation valve
flapper may only need to move away from its position blocking the secondary
flow path when
the secondary pump turns on, which for some pumping systems may be only quite
rare. As
such, the flapper of the isolation/diverter valve can experience far fewer
movements than that
of a check valve, and thereby experience much less wear and tear.
[00175] This application also describes sump pump systems that employ a
redundant
high water switch. Figure 25A shows an example of a sump pump assembly 2500
with a
redundant high water switch. Figure 25B shows the assembly 2500 of Figure 25A,
with a
portion of the high water switch housing 2516 removed to show the internal
components of
the high water switch.
[00176] The high water switch 2510 is positioned at a relatively "high"
level, above the
pumps, and is configured to activate and communicate an instruction or
otherwise activate
functionality of the assembly 2500 when water rises to or beyond a level that
corresponds to
the switch 2510. In this way, the high water switch 2510 serves as a failsafe
method for
activating the pumping assembly 2500 if other means configured to activate the
assembly 2500
have failed. That is, where water has risen to the level of the high water
switch 2510, it may
indicate that one or more pumps of the pump assembly 2500 (e.g., the primary
pump) was
not properly activated, and will default to automatically activate one or both
pumps of the
assembly 2500. Additionally and/or alternatively, activation of the high water
switch 2510
may suggest that a single pump operating is insufficient to keep up with the
current pumping
demands. In this way, the high water switch 2510 may be configured to turn on
the secondary
or backup pump in addition to the primary pump when water levels have risen to
the height
of the switch 2510.
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[001771 Figure 25B shows the internal makeup of the switch 2510 of Figure
25A, and
demonstrates the redundancy features of such a device. The switch 2510
includes a lower float
2512 and a secondary, or higher float 2514. Each float 2512 and 2514 are
configured to float on
water. The high water switch 2510 is configured so that when the lower float
2512 rises to a
certain level above a resting position, for example, because water level has
risen to that level,
the switch 2510 will activate, thereby effecting functionality of the pump
assembly 2500 (e.g.,
turning on the backup pump). The higher float 2514 serves as a redundant or
backup float in
the situation where the lower float 2512 fails to operate properly.
Additionally and/or
alternatively, the higher float 2514 can also be configured to operate as a
secondary switch
that executes additional or different functionality even when the lower float
2512 operates
properly. For example, when the lower float 2512 is activated, the pump
assembly 2500 may
be configured to activate a backup or secondary pump. When the higher float
2514 is
activated, the pump assembly 2500 may be configured to operate one or both
pumps at a
higher rate, to communicate with another system (e.g., a second backup pumping
system) to
begin to operate, or to execute a communication device to generate a warning
or otherwise
transmit a signal to a user.
[00178] The redundant high water switch 2510 of Figures 25A and B are shown
in a
housing 2516 that surrounds two floats 2512 and 2514 that serve as the
activating mechanisms
of the redundant switch 2512. In other examples, a redundant high water switch
may include
other types of switches (e.g., pressure switches, water detection switches)
that operate in a
similar fashion.
[00179] The present application also describes pump assemblies that include
a strap
handle for ease of transporting the assemblies, and/or for lowering the
assemblies into a
reservoir such as a sump pit. Figure 26 shows a configuration of a dual pump
assembly 2600
incorporating a strap handle 2602 in addition to other features. The assembly
2600 includes a
first pump 2620 (which may be an AC powered pump) associated with a first
volute 2610 and
a second pump 2530 (which may be a DC powered pump) associated with a second
volute
2612. The two pumps/volutes are cuffed together by a bracket 2660, which cuffs
a discharge
portion from each of the two pump volutes 2610 and 2612.
[00180] The discharge portions are each connected to an isolation discharge
unit 2650,
which includes two outlet flow paths 2651 and 2652 connected to fluid outlets
of each pump,
and a discharge flow path 2653. This isolation discharge unit 2650 may be or
may include any
of the isolation check valves described above. In Figure 26, the isolation
discharge unit 2650
includes a straight outlet flow portion 2652 and a curved outlet flow portion
2651. In this
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Figure, the straight portion 2652 is connected to the secondary pump 2630,
thereby providing
lower flow resistance in the discharge path of the secondary pump 2630, which
may operate
under DC power. 2600 may be removed or replaced out. The assembly also
includes a high
water switch 2670, which may be similar to, and operate in a similar manner to
the redundant
high water switch 2510 described above and depicted with respect to Figures
25A and B.
[00181] The assembly 2600 includes a strap handle 2602, which extends over
the isolation
discharge unit 2650, thereby allowing the entire assembly 2600, including the
isolation
discharge unit 2650, to be carried as a single assembly. The strap handle 2602
can be made
from a flexible material to allow the handle to be easily gripped, without
making the footprint
of the assembly 2600 larger. In some examples, the handle 2602 may be formed
from a fabric
or woven cloth material, a plastic or fiber-based material, or a rubber. The
strap handle may
be fastened to the tops of the pumps by way of snaps, buttons, rivets,
buckles, or other
fasteners, stitching or adhesives, or the handle 2602 may be wrapped around
bars or other
components of the pump assembly 2600. In some aspects, the strap handle may be
removable
so that certain components of the assembly can be more easily removed or
replaced. The strap
handle 2602 of Figure 23 can be used in connection with, or instead of the
handles 140 shown
in the embodiment of Figure 1A, which are shown as bar-type handles that may
have a more
rigid construction.
[00182] The present application also provides examples of a battery
management system,
and related methods, that allows for pumping systems and the control modules
to be
effectively controlled and operated by a battery or other finite electrical
power source. The
system facilitates evaluation of the power levels of the batteries, and may
determine whether
a battery should be charged, replaced, and/or repaired. The battery evaluation
system can
operate differently depending on the way the battery is being used. In one
example, the
battery evaluation system can be set up based on a 75 amp-hour deep cycle lead
acid battery.
[00183] The system may evaluate the charge status of the battery, but it
can also evaluate
the condition or general health of the battery. For example, as a battery
ages, its health will
likely deteriorate. Accordingly, a fully charged 8-year old battery will
likely not be as useful
as a fully charged brand new battery. This is a function of wear and tear and
general chemical
decomposition of the battery and its components.
[00184] When a pumping system is installed, the evaluation system can be
configured to
operate under an assumption that a new battery is installed and used.
Accordingly, a
processing unit of the system can be configured to form calculations based on
an initial
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assumption of a new battery, whereas additional uses and tests on the battery
will be able to
consult with measurements recorded on the battery in previously maintained
situations.
[001851 A first step for evaluation may be to charge the battery to max
capacity, for
example, the first step may involve charging the battery for at least 24
hours. After charging,
the battery may be allowed to settle for a certain time period (e.g., about
six hours) allowing
for the removal of excess charge that occurs from the charging process. The
evaluation system
can then take a voltage measurement with a simulated motor load. Via the
processing device
(e.g., a computer processor), the voltages measured may then be stored in a
database and
compared to other data which may be stored in the database. The comparison can
yield
information about the health and age of the battery.
[001861 For example, the evaluation system may compare voltage measurement
taken at
time X, where X = 2 years after the original measurement on a new battery. The
evaluation
system can then compare this voltage measurement with the information in the
database,
which may include previous measurements of the battery under test, or other
data for
reference. Based on the currently measured voltage across the fully charged
battery, and the
other measurements or information in the database, the system can determine
the health or
capacity of the battery.
[001871 Based on the comparison results, the processor may cause a display
to present an
indicator showing the status of the battery. For example, the processing
device may cause a
particular LED indicator or set of LED indicators to operate in a particular
manner so as to
indicate the battery life level. For example, a brand new battery may light an
LED associated
with a "Good" indicator, whereas a partially used battery (e.g., a battery
that has been used
for a few years), may light an LED associated with an "OK" indicator. An even
further used
battery toward the end of its life may light an LED associated with "Poor" and
a weaker
battery still may light an LED associated with a "Replace" or "Dead"
indicator. An example
of a display unit that provides the battery health information is shown in the
remote display
panel 2800 of Figure 28. In the panel 2800, the series 2820 of LED indicators
associated are
associated with LED lights that indicate the "Good," OK," "Poor," or "Replace"
status of the
battery being evaluated.
[001881 In some forms, the processing device may display the battery level
via a display
interface, for example, via a display screen that provides the battery level
as a percentage, or
that presents descriptive terms (e.g., "Good," "OK," "Poor," "Replace," etc.).
And in some
embodiments, the processing device may operate in connection with an audible
alarm that
generates an audio signal instead of, or in addition to the generation of
these visual indicators.
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[00189] As a battery ages (e.g., over a period time, such as a few years),
the voltages
measured under load will reflect lower voltage values as a result of the
chemical
characteristics of the battery degrading. The battery evaluation system is
thus configured to
perform repeated periodic voltage measurements. For example, measurements may
be
repeated about once a month, but in some situations depending on the type of
battery and the
battery's age, this measurement can be taken more or less frequently. In some
forms, this
involves subjecting the batter to a load to test battery parameters; however,
in a preferred
form, the system will use a load-free or no load battery test. For example, in
one form, the
system is set up based on a seventy-five amp-hour deep discharge lead acid
battery. When a
system is installed the unit assumes that a new battery is installed. The
system's first step is
to charge the battery for 24 hours. The battery is then allowed to settle for
six hours to remove
excess charge from the charging process. An open circuit voltage measurement
is made. The
voltages measured are compared to stored data and a battery health LED is
illuminated to
show the status of the battery. In one form, the system will signal the
following:
a new battery will illuminate a >4 Hr LED;
a worn batter (e.g., a battery that is a few years old) will illuminate a 2-4
Hr. LED;
a well-used battery (one considered more used than a worn battery) will
illuminate a 1-2 Hr.
LED; and
a weak battery (one more worn than a well-used battery) will illuminate the
REPLACE LED.
[00190] As the battery ages, over a period of years, the measured open
circuit voltages
will reflect lower voltages as the chemical characteristics of the battery
degrade. In a preferred
form, the battery voltage measurement is repeated once a month. The battery
must meet the
"fully charged" criteria (>13.9V & .75A) before the measurement is performed.
The capacity
of a fully charged battery is shown by illuminating an LED scale. Charging is
done
automatically when the pump is not running and charge current is adjusted so
as not to
damage the battery. When the DC pump is run, the control measures the current
used and
the amount of time the motor runs. Amp-hours consumed are calculated. The amp-
hours
used are compared to the latest battery health capacity measurement. An
estimate of
projected run time is made and the appropriate run time LED is illuminated
according to the
above. As a depleted battery is being charged, the control keeps track of the
charge being
added to the battery so the status of available run time is current. In a
preferred form, a newer
battery, fully charged, will show 6 hours or more run time. A poor battery
fully charged may
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only show 1-2 hours and a newer battery will likely be needed after 4-5 hours
of use of a poor
battery.
[00191] As noted, it can be most efficient if the voltage measurements are
taken on
batteries that are fully charged (e.g., the battery has been charged for at
least 24 hours before
performing the measurement). The capacity of the battery can be shown by a
different
indicator that indicates the battery life (e.g., see interface 2810 in Figure
28). The evaluation
system can also be configured to automatically charge a pump when it is not
running. The
system can also be configured to change the current, or allow a user to change
the current so
that the battery does not become damaged.
[00192] When a DC operated pump is running, certain features of the
evaluation system
can be used to measure the current used and the amount of time that the pump
motor is
running. In this way, the evaluation system can calculate and store
information pertaining to
the amp-hours used by the pump. This value of amp-hours used can be compared
to the latest
battery health capacity measurement values. Based on this calculated value,
the evaluation
system can estimate the projected run time of the pump and communicate a value
to a user,
for example, by lighting a particular LED, displaying information on an
interface, sounding
an alarm, generating a notification, or other similar techniques. The
calculated value can
represent, for example, the expected run time of the battery operating at its
current rate
without the need for further charging. As a depleted battery is being charged,
a control for the
evaluation system can keep track of the charge being added to the battery and
update the
current run time of the battery accordingly.
[00193] In some examples, a new battery, fully charged will show a run time
of 6 or more
hours. An older battery showing a poor status, even when fully charged may
only show a run
time of 1-2 hours. In some examples, the newer battery, after operating for 4-
5 hours, may still
show 1-2 hours of available run time. The panel 2800 of Figure 28 also
includes a display 2810
that provides information pertaining to the current anticipated run time of
the battery. In the
panel 2800, the series 2810 of LED indicators associated are associated with
LED lights that
indicate the anticipated run time of a pump operating under current operating
conditions
based on the current status of the battery. The calculated run time can be
based on features
such as the current operating rate of the pump, the health of the battery, and
the current charge
level of the battery, for example.
[00194] Figure 27A shows a dual pump assembly 2700 with two pumps 2701 and
2702, an
air switch 2720 and a one-piece discharge pipe 2710. The air switch 2720
includes a pressure
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tube housing that attaches to the pump assembly about an exterior side of one
of the pumps.
The air switch can be or can include the air switch depicted in Figure 18 and
described above.
The one-piece discharge pipe 2710 can be, or can include the isolation valves
or discharge
units described above with respect to Figures 21-24D and 26. For example, the
assembly 2700
may include a one-piece discharge pipe unit that includes the straight shot
portion and the
curved portion specifically depicted in Figures 23 and 26. In other examples.
By employing a
one-piece unit 2710, the assembly 2700 is "site ready" for a quick and easy
installation. That
is, the assembly 2700 can be configured to hook up to a discharge pipe at a
single location
(e.g., via the discharge outlet 2730).
[001951 In the embodiment of Figure 27A, the two pumps 2701 and 2702 are
cuffed
together via a bracket 2715, which can operate in manner similar to that of
bracket 1610 shown
with respect to Figures 16A and B, albeit with a different configuration. The
bracket 2715 is
shown in more detail in Figure 27B, separate from the pump assembly 2700. In
this example,
the bracket 2715 includes opposing annular portions 2712 and 2714 configured
to surround
collars of the two pumps 2701 and 2701, thereby embracing or "handcuffing" the
two pumps
together. The bracket 2715 is shown to have a bridge configuration with a
rounded or domed
raised portion 2735 between the two annular ends 2712 and 2714. Offset from
one of the
annular portions 2714 is a pressure tube housing support 2712, which is used
to support the
pressure tube housing of the air switch 2720, as shown in Figure 27A. In some
forms, the
pressure tube housing may have the configuration of the housing 1820 shown in
Figure 1820,
whereby the housing 1820 attaches to the housing support 2712 by way the
connection
mechanism 1825.
[001961 Figure 28 shows a remote display panel 2800 for a pumping system.
The panel
2800 provides system status and water level information as it pertains to a
pump assembly.
The panel 2800 includes a variety of LED lights that are associated with
indicators. For
example, the panel 2800 includes a battery charge level section 2810, which
includes a series
of LED lights that are associated with indicators related to the "Hours of
Protection." These
indicators may work in conjunction with the battery evaluation system
described above. As
the pump continues to draw power from the battery and the charge diminishes,
the panel
2800 will light different LED lights in the Hours of Protection section 2810
to correspond with
the currently calculated expected battery run time.
[001971 The panel 2800 also includes a section 2820 configured to display
the health of the
battery. The series 2820 of LED indicators associated are associated with LED
lights that
indicate the "Good," OK," "Poor," or "Replace" status of the battery being
evaluated. As
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described above, this battery health level is different from, the battery
charge status level
indicated in section 2810, but may be used as a basis for determining the
hours of protection
displayed in section 2810.
[00198] The battery health level can be monitored, as described above, by
periodically
performing a series of steps that include: (1) charging the battery for a
predetermined
minimum time period is sufficient to fully charge the battery; (2) measuring a
voltage across
the battery (e.g., via a simulated motor load); (3) comparing, with a
processor, the measured
voltage with information in the data store; (4) calculating the battery health
value based on
the comparison of the measured voltage with the information in the data store;
and (5)
generating a signal via the interface 2820 that indicates the battery health
value.
[00199] The data store can be an electronic storage device that is in
communication with
the panel 2800 or other components of the related pump assembly. The data
store can include
pre-loaded information, such as a look-up table, that corresponds a voltage
reading with a
particular battery health level. The data store can also be periodically
updated with
measurements taken according to the periodically performed method, so that the
battery
health level is based at least in part on the measured voltage for that
battery during previously
performed measurements. The battery charge value may be configured to
approximate a
length of time that a pump can operate on the power provided current battery
without further
charging.
[00200] As noted above, the battery health level can be used as a part of
the calculation to
determine the hours of operation displayed in interface area 2810. For
example, a brand new
battery having a "Good" health level that is determined to be half-way
depleted of charge
may display an LED associated with the indicator associated with 2-4 hours.
Conversely, an
older battery having a "Poor" health level may indicate only a 1-2 hour level
when the battery
is determined to be fully charged.
[00201] The panel 2800 also includes a display area 2830 that provides
information
pertaining to the water level in the basin. In this region 2830, the panel
will light up a certain
LED light or series of LED lights to indicate the amount of water currently in
the basin or
pump associated with the pump assembly. Using sensors associated with the pump
assembly
(including a number of the sensors described herein), the panel 2800 will
determine a detected
water level, and generate a display on interface region 2830 that presents
that water level to a
user.
[00202] The display panel 2800 may also include a power/status section 2840
that
identifies which pumps, if any, of the pump system are currently operating.
For example, the
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LED associated with the "Primary Pump" indicator will light if the primary
pump of the
system is operating, the LED associated with the "Backup Pump" indicator will
light if the
backup pump of the system is operating, and an LED associated with a "Turbo
Mode"
indicator may light if both pumps are operating. In some examples, a user may
be able to
control which pumps are operating via the panel 2800, for example, by
activating buttons or
other input mechanisms.
[00203] The display panel 2800 also includes a variety of functional
operators, which can
be a push-button feature that generates functionality when pressed by a user.
In particular,
panel 2800 includes a test operator 2850, which generates a test to assure
that the system is
operating properly when pressed. In some configurations, the panel 2800 or
other objects
associated with the panel 2800 may be configured to generate audible sounds
and warnings,
as described herein. Accordingly, the panel 2800 also includes a mute operator
2860, which
can be configured to silence or mute all audible sounds when activated by a
user.
[00204] Figure 29A is a top view of an integrated pump controller 2900 that
operates a
battery management system as described above. The controller may 2900 may be
attached to,
or rest upon a power supply, such as a battery or other DC power source that
supplies backup
power to a pumping system. The controller 2900 may also include a louvered
portion 2910
that allows air to flow to the processing equipment, which can help prevent
the control unit
from overheating.
[00205] As shown in Figure 29A, the controller 2900 includes an operating
interface with
a series of operators that can be configured to execute a variety of different
functions. For
example, the interface can include a reverse battery indicator 2912 that
alerts users when the
battery is connected to the system wrong or backwards. If the battery is
accidently connected
wrong (e.g., with the wrong polarity), then the reverse battery (or incorrect
battery
connection) indicator 2912 is displayed. While in the preferred embodiment
this incorrect
battery connection signal 2912 includes a displayed signal, such as a light,
it should be
understood that in alternate embodiments the reverse battery indicator may
include (in
addition to or in lieu of the visual display) an audible alarm to warn the
user the connection
is incorrect (preferably immediately).
[00206] A battery test/safety reset operator 2914 can perform a test on the
battery, for
example, determining a current state or health level of the battery and
display that value on
the interface. The battery test/ safety reset operator 2914 can also be
configured to perform a
safety reset of the pumping system. For example, when a tripping deice
determines that a
thermal load on a portion of the circuit has exceeded a safe operating
temperature and trips
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the circuit, the safety reset button can be operated to reactivate the circuit
(e.g., reset may reset
the thermal overload protector).
[002071 A mute operator 2916 can be configured to silence all audible
alarms generated
by the controller 2900 or associated units. In some examples, the mute
operator can be pressed
in advance of an alarm sounding and can have the effect of silencing all
alarms that may
potentially sound within a given time period. For instance, if a user will be
working on or
around the controller 2900 for a certain time period and wishes not to be
distracted by an
alarm, the user may press the mute operator 2916 to deactivate or mute all
audible alarms in
advance for a predetermined time period. The mute operator 2916 may serve to
mute all
alarms for a predetermined time period with each press. For example, the
controller 2900 may
be configured so that one press of the mute operator 2916 will serve to mute
all alarms for one
hour. The controller 2900 may allow the mute operator 2916 to be pressed
multiple times to
extend the muted period as desired by the user. For example, the controller
2900 may be
configured to allow the mute operator 2916 up to eight times to mute all
alarms in advance
for up to eight hours.
[002081 The display interface may also include the system test operator
2918, which can
be configured to effect the performance a test on the pump system to assure
that certain
features of the system are able to operate as expected. The system test can be
configured to
operate the primary pump and the backup pump to ensure that the pumps turn on
and
operate as expected, and that there are no clogs or other obstructions.
[002091 The control unit 2900 also may be connected to a display panel,
such as panel 2800
as shown with respect to Figure 28. In other embodiments, rather than (or in
addition to) being
connected to a display panel, the controller 2900 may communicate wirelessly
with a remote
device or series of devices to provide the information that could be displayed
on the panel.
For example, the controller 2900 may communicate with a mobile electronic
device (e.g., a
smart phone, tablet computer) or other computing device via the internet, a
wireless network,
or a cellular network. The device can operate an application that will allow
the user to receive
information and affect control functionality that may otherwise be available
via the display
panel (e.g., panel 2800). In some forms, the remote device operating the
application may be
capable of performing additional functionality and displaying additional
information beyond
that available by a panel.
[002101 Figure 29B is a rear view of the integrated pump controller 2900
and battery
management system of Figure 29A. As shown, the controller 2900 includes a
variety of
connection ports that allow a user to connect a variety of components to the
controller. For
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instance, the controller of Figure 29B is shown having an AC power in cord
2920 that provides
AC power to the controller, for example, via a 120-volt AC outlet or the like.
The controller
2900 also includes a power supply line 2921 that delivers electrical power
from a battery
associated with the controller 2900 to a DC powered device, such as a DC
powered sump
pump. An AC powered line 2922 provides AC electrical power to another
electrically powered
device, such as an AC powered sump pump. A remote display line 2923 forms a
communication line between the controller 2900 and a display panel, such as
panel 2800
shown in Figures 28 and 29A. An air switch line 2925 communicates with an air
switch
associated with the pumping system and facilitates the controller 2900 to
effect, cease, or
modify the operation status of the pumps of the pumping system. The backup
float switch
line 2924 communicates with the controller and serves as a redundant backup to
assure that
the pump operates as desired even where issues may arise with other primary
sensors or
operating equipment.
[00211] Figures 32A and 32B provide another embodiment of a
controller/battery
assembly 3200 that can be used in connection with a variety of the pumping
systems described
herein. The assembly 3200 includes a battery 3202 or DC power supply, which
can be stored,
for example, in a battery housing. A controller 3201 rests upon the battery
3202, and may be
attached or attachable thereto. The controller 3201 has a connection panel
3210 that allows the
assembly 3200 to connect and communicate with various equipment of the pumping
system.
[00212] Figure 32B shows a head on view of the panel 3210 of the pumping
system. The
panel 3210 comprises a variety of outlets for attachments to various sensors
and devices. A
120-volt AC input 3211 allows the controller 3200 to receive electrical power
from an AC
power source, which AC power can be used to charge the battery 3202. An AC
pump outlet
3224 allows an electrical cable to connect with an electrical device (e.g., an
AC powered pump)
and provide AC power to the device. In some formats, the AC pump outlet 3224
may provide
up to four amps of electrical current. A DC pump power outlet 3214 provides DC
electrical
power from the battery 3202 to a DC powered pump, such as a 12-volt DC pump,
which may
serve as a backup pump to the pumping system.
[00213] The panel 3210 also includes a security alarm port 3212, which can
connect to one
of various security devices including speakers or sound generating equipment,
lights or
display equipment, and/or communication devices that can send security signals
to other
remote devices (e.g., text messages). The panel 3210 may also include a
speaker and/or
audible alarm system that generates warning sounds in the event of certain
detected events
(e.g., high water warnings, pumps not operating, battery level low, etc.) In
this manner, the
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panel 3210 may include a mute button 3218, which serves to silence any such
alarm, and a test
button 3219, which allows the user to test the alarm signal to ensure that it
is operating
properly.
[00214] The panel 3210 may also comprise one or more DC pump fuses,
including a
primary DC pump fuse 3215 and a spare or backup DC pump fuse 3213.
Communication ports
3216 allow the controller 3201 to communicate with various display equipment,
such as
display panels, monitors, or other interfaces. The communication ports 3216
may also enable
communication with other equipment or communication devices, such as an
internet router,
a telephone line, a cellular network, or the like. The panel 3210 may include
ports for
connecting to various sensors, such as a water sensor port 3223 that
communicates with a
sensor that monitors the water level in a sump pit, and a back-up float switch
port 3222 that
communicates with a backup float switch that serves as a redundant switch to
any float
switches associated with the pumps of the pumping system. Vent holes 3221 on
the panel 3210
allow for air flow into the controller 3201, which helps inhibit overheating.
The panel 3210
may also include a warning system that includes a reverse polarity warning
light 3217, which
may light up or blink when polarity between the battery and the controller
and/or pumping
systems is not configured properly, thereby warning the user to correct the
issue before
initiating the supply of power.
[00215] Examples described in this application may utilize various
techniques for
controlling operation of the pumping devices. For instance, sump pump water
level can be
controlled by a float activated switch. As the water level in the sump rises
to a predetermined
level, a floating device imposes a change in the state of an electric switch,
which switch in turn
activates a pump to remove water and reduce the water to a lower level. This
level control is
normally achieved through hysteresis built into the float mechanism. Many sump
pump
failures can be traced to a failure of the switch. Accordingly, some aspects
described herein
relate to an electronic tilt switch that can be used in lieu of a float switch
or other device.
[00216] The electronic tilt switch utilizes high volume accelerometer
technology, such as
those used in portable electronic devices, to create a switch that can control
the operation of
the pumping system. An example of such an electronic tilt switch is shown in
Figures 30A
and 30B. In Figure 30A, the tilt switch 3000 takes advantage of a 3-axis
accelerometer of the
sort that may be used in smart phones or other similar devices. The tilt
sensor 3000 can be
secured to a fixed structure, such as discharge pipe 3050. The tilt switch
3000 includes a float
3020 and a hinged housing 3010. The float 3020 has an accelerometer, which can
be located,
for example, within a cavity 3022 of the float. The accelerometer is used
measure the tilt angle
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of the float. Thus, when the water level within the sump rises to the level of
the tilt sensor
3000, the float 3020 will rotate with respect to the hinge 3010, and the
accelerometer will detect
a change, and communicate with a remote circuit board via a cable 3060, or
another
communication mode (e.g., wireless communication). The supporting circuit
board can be
located remote to the tilt sensor 3000. That is, in some embodiments, the
accelerometer may
be in the float 3020, and the remaining supporting circuitry is located remote
from the
accelerometer, such as in a control unit.
[002171 Figure 30B shows the tilt switch 3000 from a rear view, where the
float 3020 is at
its highest position, having pivoted about the hinge 3010. In this view, the
water level in the
sump has risen beyond the location of the tilt switch 3000, thereby causing
the float 3020 to
pivot upwards by an angle 0. The tilt switch and/or the supporting circuitry
(which may be
within or remote to the tilt switch) can be configured to effect operation of
a pumping device
when the accelerometer detects that the float has pivoted by an angle 0,
thereby representing
a predetermined water level in a sump pit.
[002181 Figure 31 shows an example set up of a sump system 3100 utilizing
the tilt switch
3000 with an accelerometer of Figures 30A and B. The system 3100 includes a
sump pump
3110 within a sump 3105, supplied with electrical power via a power cord 3115.
The tilt switch
3000 is attached to a discharge outlet 3150. The tilt switch 3000 communicates
with a control
box 3120 via the power cord 3060. The control box 3120, powered via a power
cord 3125, can
include the various power switching electronics, which can include a single
load driving
output, such as a triac, a zero crossing device, micro-processor
transformers/dropping
resistors, a diode bridge, or the like, within a housing. In some examples,
the control box 3120
may include or be with associated LED's, alarms, and possible telephone dialer
that provide
notifications to a user. With a single electronic tilt switch 3000 the water
level will be detected
by a predetermined angle 0, as measured by the accelerometer and related
equipment inside
the tilt switch housing 3010.
[002191 In one example of operation, when the tilt sensor 3000, via the
accelerometer,
detects a level change that is greater than a predetermined value (e.g., angle
0), the
accelerometer will communicate to the control box 3120 to change the state of
the triac, thereby
effecting operation of the pump 3110. As the water level in the sump pit 3105
drops, the angle
0 will be monitored by the accelerometer. The change in the angle 0 over to
time can be
calculated by a microprocessor within the control box 3120 to establish an
appropriate off level
for the pump. In some configurations, if the triac can be configured to
activate an alarm
function to notify a user if the water level does not drop at a predetermined
rate, or to a certain
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level within a predetermined time. In some forms, the system can be configured
to activate a
second alarm function if the water level continues to rise. For purposes of
redundancy or for
controlling additional pumps multiple electronic tilt switches could be
employed.
[00220] Various embodiments described herein include cords that supply
electrical power
to the pump assembly. The cords may serve to provide AC power to an AC pump,
or to
provide a charge to a battery of a DC pump, or to connect a DC pump to a
battery. In some
examples, the various cords of the assembly will be configured so that all
cords form the same
length. This cord length matching provides users with assurance that a device
is installed
properly. Some examples of the pump assembly will include cord management
systems that
facilitate winding or wrapping of cords around the pump assembly or other
objects associated
with the assembly. The cord management systems may include spring or motor
driven cord
retraction mechanisms that facilitate winding of the cord about the pump.
[00221] Certain examples described herein describe pumps that utilize top
suction
functionality. That is, the pumps draw in fluid to be pumped from an upper
location (e.g.,
above the volute), and draw in the fluid downward rather than by sucking the
fluid upward
through a bottom portion of the pump (e.g., from below the volute). This top
suction
functionality creates a self-venting feature that inhibits air-locking
problems that can occur in
bottom suction devices. As a result, the top suction functionality allows for
the pumping
apparatus to operate without applying vent holes in the discharge pipe (which
is often
necessary for bottom suction devices), or other venting mechanisms.
[00222] The presently described technology has several applications for
use. For example,
the presently described systems and applications can be used in residential
sump pits (which
are employed in a majority of homes with basements); in rental properties
(where the tenants
may not be aware of the sump system); in vacation homes (where the occupants
may not be
present during a high water event); and/or in other locations where rising
water could cause
damage (crawl spaces, stair wells, etc.).
[00223] The present disclosure presents embodiments of tandem sump pump
assemblies
that refer to primary and secondary pumps. In some aspects the primary pump
will be an AC
powered pump and the secondary pump will be DC powered. However, in some
embodiments both pumps will be AC powered, and in other aspects, both pumps
could be
DC powered. Depending on the intended use, all embodiments described herein,
and all
references to AC pumps and/or DC pumps could be substituted for an AC/DC pump
unless
the context makes clear otherwise.
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[00224] Thus, in view of the above disclosure, it should be understood that
numerous
concepts are disclosed herein and intended to be covered herein. For example,
in one form
and as shown in final Figure 33, a back-up pump system is disclosed having a
primary AC
pump and a secondary DC pump, with the primary AC pump having a primary switch
for
operating at least one of the pumps (e.g., a solid state switch), and the
secondary DC pump
having a secondary switch for operating at least one of the pumps. We have
used similar
numbering to that show in Figs. 1A-G, 16A-B, and 18, but adding the prefix 33
to distinguish
one embodiment from the others. The system includes a back-up battery for
powering the
secondary DC pump when regular power conditions are interrupted (e.g., power
outages,
unplugged AC cord, other loss of mains power supply, etc.). A primary
controller is
electrically connected to the pumps for operating same, and a secondary
controller, discrete
from the primary controller, and electrically connected to at least one of the
pumps to operate
the at least one of the pumps when the primary controller malfunctions or
fails.
[00225] In some forms, the solid state primary switch may include a
pneumatic pressure
transducer sensor that utilizes pressure differentials to determine when one
or more of the
pumps should be operated. The primary controller may also include a processor
programmed
to activate the primary AC pump when the pneumatic pressure transducer
indicates that a
threshold fluid level has been reached. The processor may be programed to
activate the
secondary DC pump when the regular power conditions are interrupted and when
the
threshold fluid level has been reached. In addition or even alternatively, the
processor may
be programmed to activate the secondary DC pump when the primary AC pump is
not
lowering the fluid level at a sufficient rate or in a sufficient amount of
time. In some forms,
the primary controller will include a processor programmed to perform a
battery health check.
[00226] As mentioned above, some embodiments will have a battery charging
circuit
electrically connected to the back-up battery for charging the battery and
regular power
conditions are present, and having a battery health monitoring circuit for
monitoring battery
health. The battery health monitoring circuit may include a display for
displaying indicia
indicative of the battery health and an alarm for alerting a user to a problem
with the battery
based on the monitored battery health. The term alarm is used broadly to mean
any type of
audible alarm (buzzer, speaker, siren, etc.), visual alarm (e.g., light, flag,
display, etc.) and/or
an electronic message alarm (e.g., text, app notification, auto-call or voice
message, etc.).
Similarly, the term display is used broadly to mean any type of light, digital
display (e.g., LED
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display, LCD display, touch screen, plasma display, numeric display, etc.),
analog display,
and/or a mechanical indicator (e.g., flag, indicator, etc.).
[002271 In a preferred form, the primary controller includes a
communication device for
transmitting notifications about the pump system to a user. The communication
device may
include a transmitter or transceiver for connecting the primary controller to
a wireless
network to transmit the notification via the network. A transceiver is
preferable to allow two-
way communication and user interaction with the pump system to get information
from the
pump system (e.g., real-time status, diagnostic analysis, historical data,
such as performance
data, etc.).
[002281 In some forms, the pumps system is connected to a discharge pipe
via one or more
check valves. However, in other forms, the primary AC pump and secondary DC
pump are
connected to a diverter valve that diverts fluid flowing from one of the pumps
toward a
discharge pipe that the pump system is connected to and hinders fluid from
backflowing or
recirculating back into the other pump (e.g., the diverter prevents one pump
from pumping
fluid back or backwards into the other pump to prevent flooding, etc.). In a
preferred form,
the diverter valve includes first and second inlets, one common outlet and a
diverter body
positioned between the inlets, the first inlet being in fluid communication
with the primary
AC pump and the second inlet being in fluid communication with the secondary
DC pump,
and the diverter body being movable between: a first position wherein the
diverter body
blocks the second inlet and allows fluid to flow from the primary AC pump to
the common
outlet while hindering fluid flow into the second inlet; and a second position
wherein the
diverter body blocks the first inlet and allows fluid to flow from the
secondary DC pump to
the common outlet while hindering fluid flow into the first inlet. The first
fluid passage
extending between the primary AC pump and the common outlet may include a
curve or
bend, and the second fluid passage extending between the secondary DC pump and
the
common outlet may form a generally linear fluid passage which allows the
second fluid
passage to provide less fluid resistance than the first fluid passage to allow
the secondary DC
pump to operate more efficiently since it is powered by the battery and not an
AC power
supply. In some instances it is preferable to have the AC pump side of the
system deal with
plumbing bends and turns that cause loss or greater fluid turbulence and
inefficiencies since
AC power seemingly is available for extended periods of time compared to the
DC power
provided by a battery (e.g., batteries have battery life and it is desirable
to setup the system to
maximize efficiencies that conserve the battery power life). In the forms
illustrated, the curve
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or bend of the first fluid passage is between 450-900 (e.g., the bend in the
plumbing or piping
from the AC pump to the outlet pipe) and the second fluid passage is coaxially
aligned with
the discharge pipe (e.g., a straight or straighter shot).
[00229] Also disclosed herein is a pump system having a connector for
connecting the
primary AC pump to the secondary DC pump so that the pumps may be moved or
placed
together as an assembly. In the form illustrated in Figure 33, the connector
33610 is a coupling
that has a first interface 33614 for aligning with a first AC pump 33130
outlet and a second
interface 33612 for aligning with a second DC pump 33120 outlet so that the
pumps may be
connected to one another and moved or placed together as an assembly. A raised
arch
connects the first and second interfaces 33614, 33612 of the coupling 33610.
The first interface
33614 is connected to the first AC pump outlet via a first fastener 33631 and
the second
interface 33612 is connected to the second DC pump outlet via a second
fastener 33630. The
first AC pump outlet and second DC pump outlet each have internal female pipe
threading
(FPT) and the first fastener and second fastener are threaded sleeves each
having male pipe
threading (MPT) on one end that mates with the FPT of the first AC pump outlet
and second
DC pump outlet, the fasteners further each having a flange portion that
engages respective
portions of the coupling to secure the coupling to the pumps and the pumps to
one another.
In the form illustrate in Figure 33, the flange has flat edges to form a nut-
type threading that
a wrench can be used with and/or engage to tighten the sleeve to the pump and
clamp the
coupling between the sleeve and the volute. Seals (e.g., rubber sealing rings,
washers, etc.)
may also be sued to improve this connection. In the form illustrated in Figure
33, the coupling
further includes a portion for connecting at least a portion of the pneumatic
pressure
transducer sensor to in order to position the at least a portion of the
pneumatic pressure
transducer in a desired position in relation to the pumps. The portion
protrudes out from one
of the interfaces of the coupling (e.g., 33612) to position a hollow housing
33820 of the
pneumatic pressure transducer sensor proximate the side wall of one of the
pumps (e.g., DC
pump 33120).
[00230] In other forms mentioned above, the connector may be a first mating
member
connected to the primary AC pump and a second mating member connected to the
secondary
DC pump and the first and second mating members mate with one another to
connect the
pumps to one another. For example, the first mating member may be one of a
male or female
mating structure and the second mating structure the other of a female or male
mating
structure so that the mating members interconnect with one another to connect
the pumps
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together. In one earlier form, the volutes were formed with such structures to
interconnect
the volutes and, thus, the pumps to one another.
[00231] The connector may also include other items that also help connect
the pumps to
one another. For example, in Figure 33, the connector is also a member that
extends from a
top or side surface of the primary AC pump to a top or side surface of the
secondary DC pump
to connect the pumps together. In the form illustrated, the member is a handle
33140 that
interconnects the pumps so that they can be carried or placed as a connected
assembly. In
some forms, two such handles have been shown made from metal and
interconnecting the
top of the pumps. In other forms illustrated herein, this form of connector
has been a fabric
strap. Regardless of its ultimate form or shape, it may be helpful to use
multiple forms of
connectors in order to securely connect one pump to the other so that they
travel and place
well. For example, having a first connection between the lower portions of the
pumps (e.g.,
the pump outlets, e.g., volute outlets) and a second connection between the
upper portions of
the pumps (such as the handle interconnecting the tops of the pumps) helps
form a stable
connection between the pumps and one that allows for easy carry and placement.
AC power
cord 33104 and DC power cord 33102 are also illustrated in Figure 33.
[00232] In addition to the above and as illustrated in Figure 33, the
plumbing or piping of
the pumps forms yet another connector that connects the pumps to one another.
This PVC
piping forms a cross-over connection between the two pumps that establishes
yet another
connection point or portion between the two pumps. In a preferred form, the
handle will
extend over the top of this piping in order to encourage the connected pump
assembly to be
carried by the handle and not the piping or plumbing. In the form illustrated
in Figure 33,
each pump has a check valve connected downstream of the pump outlets (e.g.,
volute exits),
and preferably downstream of the coupling that interconnects the volutes. Then
the cross-
over plumbing or piping connects the respective check valves to a common
outlet pipe which
can be connected to a common discharge pipe of the system via a simple rubber
sleeve
connector (or coupling) connected to the discharge pipe and the common outlet
pipe via hose
clamps or the like. The check valves prevent either pump from pumping fluid
backwards into
the other pump (e.g., recirculating or backflowing fluid into the other pump).
However, in
alternate embodiments similar to those discussed above, the pump assembly
could be
configured with a single isolation valve (e.g., diverter valve) to be used in
lieu of the dual
check valve configuration.
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[00233] It should be understood that the embodiments discussed herein are
simply meant
as representative examples of how the concepts disclosed herein may be
utilized and that
other system/method/ apparatus are contemplated beyond those few examples. For
example, while an AC pump and DC pump system is described as preferred, it
should be
understood that this disclosure contemplates using two AC pumps or two DC
pumps, etc. In
addition, it should also be understood that features of one embodiment may be
combined
with features of other embodiments to provide yet other embodiments as
desired. Similarly,
it should be understood that while the system/method/apparatus embodiments
discussed
herein have focused on sump pump systems, other uses of the solutions
presented herein are
contemplated, such as the use of other type of pumping devices.
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