CROSS REFERENCE TO RELATED APPLICATIONThis patent application is related to and claims priority from U.S. Provisional Patent Application Ser. No. 61/355,635 filed Jun. 17, 2010.
FIELD OF THE INVENTIONThe present invention relates, in general, to sump pumps and, more particularly, this invention relates to a sump pump system having improved remote control and monitoring.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENTN/A
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIXN/A
BACKGROUND OF THE INVENTIONAs is generally well known, sump pump systems, particularly for industrial applications, are equipped with sophisticated operating and monitoring controls.
However, it has been found that there is a need for an improved sump pump system, particularly in the area of remote control and communication.
SUMMARY OF THE INVENTIONThe present invention in several embodiments is a sump pump system with selectable system settings. The selectable settings could comprise: size of pump (for proper failing of bad pump); type of battery (for proper charge routine); type of control switch; single or dual pumps or more, self testing frequency; AOK frequency; pump run time; and alarm settings.
A selectable pump operation could comprise: primary—no alarm will be created because of pump operation; backup—default mode (alarm will sound if pump operates); controlled—system's pump is controlled by dual float reed sensor; and mechanical—system's pump is controlled by any standard mechanical switch (float, pressure, etc.).
In controlled operation, a pump's run time may be adjusted between 5 and 90 seconds or zero may be chosen and the controller may turn off the pump when it detects that the pump has finished pumping water.
The system can immediately recognize a problem with any sensor and enter Emergency Mode. Since the controller has determined that a sensor cannot be relied on, it will turn the pump on to check for water to pump at scheduled intervals or some other arraignment.
In emergency mode, the system could extend the interval run time checking for water from 1 minute, to2, to4, up to 8 minutes. Once it detects and pumps water the interval will reset to 1 minute or another predetermined interval. This will save battery time during a period of no or slow rainfall or other low flow situations.
The controller may be set for dual system operation. The operation of dual pumps is selectable between “Related” or not. This feature allows pumps in separate sumps to operate independently if water levels rise and fall unequally.
The present invention in several embodiments comprises an expandable data network to allow for additional peripherals and functionality. Self-testing may be set to be configured at any desired interval. Alarms from testing or events will be sent to user via text, email, instant message or other electronic telecommunication means. Each alarm message can include the remote access and local access links so user may click and open a remote interface of their pump anytime, from anywhere. Interface allows alarm management, equipment testing, and editing of all settings.
Auxiliary alarms may be sent using the controller's Ethernet/internet, dialer, or home security system for any auxiliary sensor the user chooses to employ. i.e. water level sensor in ejector, temperature sensor for freezer (or in the home itself), motion, window breaks, door jam sensors, etc.
The present invention may comprise integrated service alerts/reminders. Owner could receive text/email alerts when equipment ages past pre-set values. Alerts may be sent to contractor so that 3rd party monitoring is possible for homeowner. Professional (paid) monitoring is also possible and remote access by Professional monitoring contractor provides unprecedented access and control to the flood prevention system.
A report on the status of important functions can be viewed on unit, and is also copied into alarm messages for easy user reference. A user may elect to receive A-OK notifications. These messages are useful when there are no events or alarms, yet the homeowner wishes to receive positive confirmation that all is well with the system. In several preferred embodiments the system can be remotely controlled and monitored through the internet.
Several preferred embodiments of the present invention are configured as a whole house control system or house utility and appliance control system. Multiple additional units can be added to the system to enable further envisioned functionality.
The pump system can monitor additional pump locations, such as the ejector pump by means of an auxiliary float sensor. In several embodiments the unit can speak alarms and menu navigation.
A primary electric sump pump utilizes a local control unit to monitor standard operation and is connected to the invention utilizing a data network. This allows for several advantages, such as primary pump self-testing, failure prediction, and remote control, monitoring, and management. Data on pump operation can be tracked and displayed for homeowner on a controller online interface.
A thermostat utilizes the invention to allow users simple remote access and control of the home's temperature. The new thermostat is wired into the home's HVAC system and is controlled by the user via the internet through the controller data network. User is now able to view and adjust temperature remotely and set alarms for high or low temperature thresholds.
The system in several embodiments allows for remote access and control of an electric generator. User benefits by means of testing to verify the system is ready for emergency start-up. This is particularly useful when an emergency is anticipated.
OBJECTS OF THE INVENTIONIt is therefore one of the primary objects of the present invention to provide a sump pump system that overcomes the disadvantages of the prior art.
Another object of the present invention is to provide a sump pump system that can be remotely monitored and operated.
Yet another object of the present invention is to provide an intelligent sump pump control system.
BRIEF DESCRIPTION OF THE DRAWINGSFIG. 1 is one 3-d view of a sump pump system of the instant invention;
FIG. 2 is another 3-d view of a sump pump system of the instant invention;
FIG. 3 is a block diagram of a control system for controlling the sump pump ofFIGS. 1-2;
FIG. 4 is a block diagram of a controller employed within the control system ofFIG. 3;
FIG. 5 is a block diagram of a LED module employed within the controller ofFIG. 4;
FIG. 6 is a block diagram of a LCD module employed within the controller ofFIG. 4;
FIG. 7 is a block diagram of an Ethernet module employed within the controller ofFIG. 4; and
FIG. 8 is a block diagram of a communication module employed within the controller ofFIG. 4.
BRIEF DESCRIPTION OF THE VARIOUS EMBODIMENTS OF THE INVENTIONIt is to be understood that the definition of a sump pump applies to pump adapted to remove liquid, for example such as water, from a sump pit structure.
Reference is now made, toFIGS. 1-8, wherein there is shown a sump pump system, generally designated as10, for removing water or other liquids fromsump pit structure1.
Furthermore,system10 is illustrated and described as a back-up system to be used in combination with an existingsump pump2, generally of an AC type. Thepump2 is connected to itsown discharge manifold4 having acheck valve6 installed therewithin.
Now in a particular reference toFIG. 1, thesystem10 is illustrated and described as having apump12, preferably of a DC type, connected to thedischarge manifold14. Afirst check valve16 is installed, in a conventional manner, within thedischarge manifold14. Mounted on a lower portion of thedischarge manifold14, within thesump pit4, are lowwater level sensor18 and a highwater level sensor20. The discharge manifolds4 and14 can be connected therebetween with awye8.
Thesystem10 ofFIG. 1 also includes aprimary battery40 and a back-upbattery42.
Thesystem10 further includes a control system, generally designated as50 and best illustrated inFIG. 3. Now in reference toFIG. 4-8, one of the essential elements of thecontrol system50 is acontroller52. Thecontroller52 includes aprocessor54, a battery charging andpower supply circuit56, acommunication interface58, a plurality of inputs60-68, and a plurality of outputs70-74.
Connected to theprocessor54 by way of thecommunication interface58 areoptional LED module80,LCD module110,Ethernet module130 capable of two way communication by way of local area network (LAN) or internet and communication (“Talking”)module140.
Thesystem10 also provides for optional remote control/display unit150 operatively coupled to thecontroller52, capability to link thecontroller52 with anetwork computer160 and a wireless control and monitoring capabilities with a wireless hand helddevice170, that may be a conventional cell phone or the like devices.
Installation of the main components of thesystem10 is achieved in a conventional manner. In further reference toFIG. 1, pump12 is mounted in thesump pit1.Discharge manifold14 is also installed and is connected to thepump12.Sensors18 and20 are preferably mounted on thedischarge manifold14 above theelectric pump12.Controller52 andbattery40 are installed in a designated location.Controller52 is coupled to the supply of electric power, such as a standard110v wall receptacle6.Pump12 andsensors18 and20 are electrically coupled to thecontroller52.
General operation of thesystem10 is as follows.
Upon power-up, all LEDs will illuminate and the alarm will chirp 5 times to indicate proper operation. After 2 minutes, thesystem10 will perform its first self-check, followed by a battery recharge.
When water engages (lifts) thelower sensor18, thepump12 turns on. The owner can choose the method by which thepump12 turns off in the Switch Type Mode (described in further detail in Mode section). Once thelower sensor18 disengages, either thepump12 turns off after a set amount of time expires, adjustable by the user, or by recognition of the lack of water to pump12 (default). If water reaches theupper sensor20, a high water alarm is triggered. Theupper sensor20 also functions as a redundant sensor to control thepump12 in the event that thelower sensor18 fails.
Controller52 will run thepump12 directly using its internal power supply, completely by-passing thebattery40. In fact, thecontroller52 is capable of running thepump12 without any battery attached, though this is not recommended. When AC power is present, thecontroller52 will maintain the battery(ies) at a full charge using a multi-stage charge routine, the charging style proven best for these batteries in this application.
At preselected intervals, for example twice per day, thecontroller52 will enter an auto-test mode and verify that all equipments are operating properly. Included in the test routine is: test run thepump12, load test thebattery40, test all LEDs and alarm for continuity and operation, verify charge operation, verify internal circuit integrity, check that the water level sensors are working properly, and finally, empty the sump of water. Once every 2 weeks, the charge mechanism of thecontroller52 will not only perform a thorough recharge of thebattery40, but also initiate a “desulfation” technique. This attempts to break down naturally occurring sulfate on theinternal battery40 components, resulting in a longer lasting andstronger battery40.
All configuration and history information is permanently saved and is not affected by a power outage and/or disconnection from thebattery40.
Depending on the status of thecontroller52, the 16 character, 2 row bluebacklit display12 will be relating specific information to the user.
- During normal stand-by: “System10 Ready”
- During power outage: “Battery40 voltage, amps being drawn, remainingbattery40 %, remaining running time” (calculated using the # of available ampere hours,battery40 age, and the cycling behavior)
- During charging: “Amperage output, % charge complete
- During all user interaction: applicable menu navigation information
All 4 LEDs90-96 should be on solid in stand-by mode. If one or more LED is flashing, an error or alert is present. LEDs90-96 also have a Double flash indicator state.
- Red ‘Power’ LED90: Solid: AC power is present, Flashing: AC power is out. Double flash:Pump12 Activation (will not flash ifcontroller52 inPrimary Pump12 Mode)
- Yellow ‘Charge’ LED94: Solid:Controller52 has successfully chargedbattery40. Flashing:Controller52 is chargingbattery40. Double flash: Fuse problem
- Green ‘Stand-by’ LED, Solid:system10 ready, Flashing: sensor malfunction, Double Flash:Pump12 on continuous
- Blue ‘Battery40’LED100, When AC power on: Solid:Battery40 OK, Flashing:Check Battery40. Double flash: during power outage,battery40 below 50%, seek alternative power
There are 6 buttons total. Every press of a button will coincide with a confirming beep.
The 2 buttons below thedisplay112 correspond to user interface information shown in thedisplay112. The 4 remaining buttons are “Speak”84, “Silence”82, “Notify”89, and “Mode”86.
“Speak”button84 will give the user the ability to hear thecurrent system10 status, verbal alerts, and menu navigation. After the current status is stated, the user is given choices of hearing the results of the last 3 test routines, the last 3 alerts, and verbal confirmation of all settings.
“Silence”button82 makes thecontroller52 immediately stop beeping. However, the alarm will not clear out until a second press of thebutton82 occurs. This allows the user to still inspect thedisplay112 for the reason for the alert or press the “Speak”button84 to hearsystem10 status even after a single press of theSilence button84. Thedisplay112 will query the user if the beeping and alerts should discontinue for 24 hrs. If yes is chosen, thecontroller52 will not beep or initiate a notification for the same alert for 24 hours. After 24 hours, if no new alerts have been issued, the alert will clear from memory and thecontroller52 will return to Stand-By. If the user wishes to clear the alarm from thecontroller52 immediately, a second press ofSilence button82 will remove the alert from memory. Note that if the same alert occurs, the alarm and notification process will again initiate.
Example uses of a single press vs double press of Silence button82: if the alert is for apump12 activation because the primaryelectric pump12 has failed, and the sump activity will require thepump12 to activate frequently, it is better to press the Silence button once to discontinue beeping and alerts for 24 hours rather than pressing the Silence button twice, which will clear thepump12 activation alert completely from thecontroller52 and allow thecontroller52 to beep and notify if thepump12 turns on again. On the other hand, thecontroller52 might be alerting because you disconnected thebattery40. Once thebattery40 has been reconnected, you will want to doublepress Silence button82 to not only stop the beeping, but also clear the alert out of memory and reset thedisplay112 to Stand-By mode.
“Notify”Button89 is for all information related to the alert triggers. You can also dictate settings regarding dialer setup, home security system connection, and internet connection. User can customize what triggers will initiate the notification process.
- User can toggle through a notification history. (since no time clock,display112 could label each trigger with an approximate time stamp, i.e. “131 days ago” etc.)
- The user is also given the choice of sending a “test” trigger to immediately initiate the notification process.
- ‘Mode’button86 allows you to toggle through many different modes.
Pump12 Mode: select between ‘Primary’ and ‘Backup’ modes. When in ‘Backup’ mode,system10 will operate in stand-by as abackup pump12system10, therefore alerting owner uponpump12 activation. ‘Primary’ mode will operate thesystem10 as though it is theprimary pump12 unit, therefore not alerting to pump12 operation. Default=Backup
Silent Mode: immediately disengages current audible alarm. The user is given the choice of silencing the alarm for any period of time or permanently. If Silent mode is chosen, thedigital display112 will momentarily blink every 2 seconds. Also, permanent yes/no beep settings can be made for each alert. This will not affect thecontroller52's decision to initiate a notification for the alert. Default=all alarms on
Reset Mode: clears all existing LED90-100 alarm conditions and silence all existing audible alarms. As soon as an alarm condition presents itself again, the corresponding lights and audible will again occur.
Override Mode: runs thepump12 non-stop when set to ‘on’. This is much like a panic switch to verifypump12 operation. Presently preferred Default=off.
Run Time Mode: dictates the amount of time thepump12 will run onceSensor1 is deactivated. (vary from 5 to 60 seconds) Presently preferred Default=15 seconds.
A-OK Mode: set to on to receive a regular “all clear” phone call from the ePump 122Series controller52. User may set call interval to any frequency desired or to not frequency. User may adjust A-OK call time from current time in 15 minute increments. Presently preferred Default=weekly.
Volume Mode: will adjust the volume of the Speak function. The volume of the alert beeper may not be adjusted. Presently preferred Default=75%.
Test Mode: will initiate the normal test routine. The test time and interval is adjustable by the user. The choice is also given to reset the self-test time to the current time and then adjust the self-test time up or down in 15 minute increments from the current time.
ID Mode: will display112 the unit's serial number and software version.
Battery40 Mode: User can initiate a recharge process. User can tellcontroller52 that batteries are new. User can set the number ofbattery40 ampere hours (battery40 capacity) thecontroller52 is connected to. Range is from 80-440. Presently preferred Default=110.
Switch Type Mode: User can choose to use a mechanical pump switch rather than the standard dual float sensor. Choosing “Mechanical Switch” will turn off thecontroller52's “Timed Off” function for turning off thepump12, and turn off thecontroller52's ability to test/monitor the sensor. Instead of the pump off being on a timer, the Mechanical Switch itself will turn thepump12 on and off. Presently preferred Default=Sensor.
Pump12 Type Mode: User can use this setting to select a different amp range ofpump12 operation. Detection ofpump12 operation outside of the set range will cause pump12 failure notifications. This setting should NOT be changed unless thepump12 being plugged into thepump12controller52 is NOT the normally includedpump12Black Label pump12. It thepump controller52 is being used with anotherpump12, you will need to call 800-xxx-xxxx and describe the brand ofpump12 being utilized. We will then tell you the proper setting to use.
System10 Data Mode: User can toggle through accumulatedController52 Hours, Pumping Hours (alert when 3,000 hours is reached), Number of Alerts.
All alerts will trigger the notification process in 5 minutes after detection. Exceptions are the immediate alert for high water, and 30 minute delay for power outage. Thecontroller52 will initiate alerts for the following triggers:
Pump12
- Activation
- Jammed pump
- Over/under amperage
- Dead pump
- Life timer exceeded
- Reversed polarity
Battery40
- Over/under voltage
- Failed load test
- Disconnected
- Limited remaining run time
- Reversed polarity
Sensors18-20—Disconnected sensor
Power Outage—30 minute notification delay
Continuous Run. Could simply be caused by large inflow of water and pump12 running continuous. Also could indicate problem related to:
- Clogged piping
- Frozen piping
- Air locked piping
High Water Sensor. Water level has risen to the level of the top sensor. Immediate notification.
Internal Failure.Controller52 has detected a problem with the power supply, circuit board, or other internal component.
Failure to notify, unit will alarm and display112 alert locally if any attempt to notify (including test, self test, or A-OK call does not complete properly)
Not only is thesump pump system10 the highest pump12ing capacity system10, and the mostsophisticated technology system10, it is also the world's first and only “Connected”system10.
The user has 3 choices to achieve notification:
1. The simplest method for notification is to utilize your existing home security system180 (such as ADT, Protection One, Keyth, etc.). This is achieved by purchasing the optional Security System Transmitter (SST)182 and simply plugging it into the corresponding port on the bottom of thecontroller52. ThisSST182 can be purchased from your point of purchase OR from your home security system provider. TheSST182 will need to be “synched” to your control panel and yoursecurity system180 provider may charge you an additional monthly fee to add this as a monitored location. TheSST182 will initiate an alert to thesecurity system180 provider for any of the alerts you have defined as part of the notification process.
2. A second method of notification is to utilize theoptional wireless dialer172, called the DataDispatch. This is a programmable dialing unit that will call up to 5 programmable phone numbers and play your custom message. The DataDispatch, which can be located at an available phone jack anywhere in your house, is wirelessly triggered by a transmitter plugged into the bottom of thepump12controller52.
3. The most thorough method of notification, and the method that takes advantage of all thepump controller52's remote access/control capabilities is to connect the unit to the internet. This method does not require any additional accessories. You simply plug one end of an ethernet cable into the RS485 port on the bottom of thecontroller52 and the other end into an available port on your network. Configuration of the unit into your network is beyond the scope of this manual. The variances between network settings, routers, and security vary too greatly for this manual to make any useful attempts at covering the subject. Basically, you or a knowledgeable networking person need to have the home's router recognize thecontroller52 and assign it an address on the network. Then use an internet browser to navigate to thepump12controller52 user interface (similar in look to web pages) and configure the notification settings (email, etc.). If you wish to configure the settings so that you can access thepump12controller52 from outside of your LAN (i.e. from anywhere else in the world besides the location of your router), your router must be set to assign thepump12 controller52 a static IP address. These configuration requirements are typically a simple 2 hours of setup for somebody with moderate networking skills. However, this can vary from 10 minutes to unknown depending on the existing hardware and settings.
Once the method of notification is selected and set up, we recommend testing the notification process by simulating an error condition such as an unplugged sensor.
Thecontroller52 is equipped with aninternal speaker148 that will sound for several reasons.
A 3 second delay beep indicates that thepump12 is currently running. The alarm switch can be set to ‘off’ if desired
A 6 second delay beep indicates abattery40 problem. Checkcontroller52 for LED and/or LCD indication of problem.
A 3 second delay double beep indicates some other problem (pump12 jam, connectivity, polarity, etc.). Checkcontroller52 for LED and/or LCD indication of problem.
A 6 second delay double beep indicates loss of power.
In addition to theaudible alarm102, thecontroller52 contains an internal speaker that will verbalize the current error condition. See the section above regarding the “Speak” button.
Bottom Panel of thecontroller52.
The various receptacles and cords on the bottom panel of controller52:
AC power cord. If possible, plug thecontroller52 into a dedicated circuit. Plug unit into standard electrical power receptacle that, if shared, is shared by a combined amp draw less than the rated circuit allows. Plug this cord in BEFORE attaching the DC cord to batteries.
“Pump12” receptacle, to plug in the plug from thepump12.
“Sensor” receptacle, to plug in the plug from the sensor.
“Remote Display112” receptacle, to plug inoptional Remote Display112 Unit.
“Notify” receptacle is for an RJ11 plug that can plug into the included wired dialer, the transmitter for the upgraded wireless dialer, or an existinghome security system10.
DC power cord. For connection to the batteries. Connect tobattery40 AFTER pluggingcontroller52 in to AC power.
Sold as an option, the user may purchase the Remote Control/Display device150. Thisdevice150 may be placed at any location in the home for easy access to all user controls. It connects to thecontroller52 via either wired connection, for example by way of aRS 485 protocol, or wirelessly. Thedevice150 gives the user a convenient “at a glance” access to thesump pump system10. All the buttons, LEDs, and display112 are repeated on theRemote Display Device150 for 100% control and input of thesystem10.
The optional pump serieswireless notification unit172 can be placed next to any desired phone jack (up to 50′ away) and is signaled by thepump series controller52 wirelessly. Simply plug in the includedwireless transmitter172 to the “Notify” jack on the bottom of thecontroller52. The device will dial up to 5 different phone numbers to notify you of an alert condition. This upgradeddevice172 can also accept triggers from up to 60 additional wireless accessories such as sensors for windows and doors, temperature, motion, water level in ejector pit, etc.
The afore-describedsystem10 is one-of-a-kind, technology-infusedsump pump system10 that will operate as an AC or DC system with maintenancefree batteries40,42. It is also design to pump the most water of any currently availablebackup pump system10, achieve the longest running times in the industry, self test all components and confirm the absence of faults or errors twice per day, communicate the presence of any faults through itsdigital display112, and loud internal beeper and phone, email, and text notification through one or more of the following: existinghome security system10, phone messages to up to a plurality of phone numbers, or internet connection.
In addition to the notification capabilities, thesystem10 also has the unique “Speak”button84 which, when pressed, will state, in clear English, the unit's status and menu flow.
User interaction is accomplished through a high tech,intuitive display112 panel with a 2 line, 16 character Blue backlitdigital display112, 4 LEDs114-120, and 6 blister buttons82-88 and122-124.
Thecontroller52 permanently stores most recent alarm andsystem10 information in its memory.
Occasionally, a second pump is desired for increased pumping capacity augmenting thepump12.
Accordingly, in reference toFIG. 2, thesystem10′ is illustrated and described as having afirst pump12 connected to thedischarge manifold14. Afirst check valve16 is installed, in a conventional manner, within thedischarge manifold14. Mounted on a lower portion of thedischarge manifold14, within thesump pit1, are lowwater level sensor18 and a highwater level sensor20. Thesystem10 also includes asecond pump22 connected to thedischarge manifold24 having itsown check valve26. Thesecond pump22 is also of a DC type. Themanifolds14 and24 are preferably connected therebetween into acommon discharge manifold28 connected with themanifold4 by way of awye8.
Thesystem10′ ofFIG. 2 will allow for asecond pump22 to be used along with a “slave”controller53. Theslave controller53 simply plugs into thefirst controller52 via a data cable and control of bothpumps12 and22 is now achieved.
The instant invention further contemplates that thepump2 can be connected either tocontroller12 or to anotherslave controller53.