TAN TANITIKAN UIT USIN VIATA20170234117A1 MA MA MA MA MA MAN UNITI ( 19) United States (12 ) Patent Application Publication (10 ) Pub. No. : US 2017 /0234117 A1 Kidd et al. (43 ) Pub. Date : Aug . 17, 2017 ( 54 ) METHOD OF CONTROLLING A PUMP AND E21B 47 / 06 (2006 .01 ) MOTOR F04B 47 /06 (2006 . 01) E21B 47/ 00 (2006 .01 ) (71 ) Applicant: Pentair Flow Technologies, LLC , 2 ) U . S . Cl. Delavan , WI (US ) CPC ...... E21B 43 / 126 ( 2013 .01 ) ; F04B 47 / 06 ( 2013 . 01 ) ; E21B 47 /0007 ( 2013 .01 ) ; E21B (72 ) Inventors : Melissa Drechsel Kidd , Muskego , WI 47 /06 ( 2013 .01 ) ; E21B 41/ 0092 ( 2013. 01 ) ; (US ); William James Genaw , Pewaukee , WI (US ) ; Micheal Pasche , H02P 25 /02 ( 2013 .01 ) Sharon , WI (US ) ;Gary T . Baase , II , (57 ) ABSTRACT Kenosha , WI (US ) A variable frequency drive system and a method of control ling a pump driven by a motor with the pump in fluid (21 ) Appl. No. : 15 /421 , 251 communication with a fluid system is provided . The method includes monitoring a pressure in the fluid system , moni ( 22 ) Filed : Jan . 31, 2017 toring and adjusting an operating frequency of themotor to Related U . S . Application Data maintain the pressure at a pressure set point, and , based on the monitored operating frequency, causing the pump to (63 ) Continuation of application No. 12/ 481, 435 , filed on temporarily boost the pressure in the fluid system to a Jun . 9 , 2009 , now Pat . No . 9 , 556 , 874 . temporary boost set point for a first time period . The method also includes determining whether the temporarily boosted Publication Classification pressure in the fluid system stays above the pressure set ( 51 ) Int. Ci. point for a second timeperiod and causing the pump to enter E21B 43 / 12 ( 2006 .01 ) a sleep mode when the temporarily boosted pressure stays E21B 41/ 00 ( 2006 .01 ) above the pressure set point through the second time period .
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FIGURE 11 Patent Application Publication Aug. 17, 2017 Sheet 12 of 64 US 2017 /0234117 A1
recomanda r e PID MODE 130 128 132 ti . . . whois RESET BOOST CarmenFREQ STABLE INCREMENT DELAY TIMER NO WITHIN + 1- 3HZ2YES BOOST DELAY Kicsiminin TIMER www . updated on toode S INCREMENT TO BOOST YES. BOOST kopplina YES. paintingDELAY TIMER osastoinenNieminen. DIFFERENTIAL hingamiEXPIRED B OVER 15 SECS n apier p oegangIS PRESSURE 34 t 136 MA BETWEEN SET ANDmahigwybrymint 142 35k SET DIFF Humanitariniai Daribarang tida noongoooooo DECREMENT TO 140 HAS 15 BOOST peSECONDStabiiy YES DIFFERENTIAL PASSED alitateZ OVER 15 SECS YÉS c papoor 138 Lo senderimisest potesishtHAS 15 TS PRESSUREpici NO 148 P- YES.. SECONDS NOur BETWEEN SET ory PASSED the spirit AND SET+ DIFF within 1S PRESSURE u ABOVE SETPOINT Porno 144 m icon
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PID MODE DOODPOROS RESET TIMER 156 d WR PRESSURE NO markKertuin 20 PSI ABOVE chichi ??????? ?????????????? : SETPOINT porttitor INCREMENT 158 sinemitting TIMER
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DIGITAL INPUT 182 184 WHEN PAR 1920 = UNUSED = HIGH DO NOTHING 190 Batterier (DO NOTHING 88 WHEN PARA 186 FLOW 920 RUN HIGH ENABLE DRIVEom DRIVE STOPPED RUNNING YES 198 DO NOTHING DO NOTHING NO
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RELAY OFF RELAY ON 234 FIGURE 16 Patent Application PublicatioPublication Aug. 17, 2017 Sheet 16 of 64 US 2017 /0234117 A1
240 . . . . . SETTINGS MENU werp UP /DOWN 242 MOTOR UP /DOWN
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PRO WA ENTER
BOOST DIFFERNTIAL ENTERCHANGE VALUE PAR 971 sitoimiinibining and Romanonene 284 270 UP /DOWN ENTER
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FIGURE 20 Patent Application Publication Aug. 17, 2017 Sheet 21 of 64 US 2017 /0234117 A1
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FIGURE 21 Patent Application Publication Aug . 17 , 2017 Sheet 22 of 64 US 2017 / 0234117 A1
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FIGURE 22 Patent Application Publication Aug. 17 , 2017 Sheet 23 of 64 US 2017 / 0234117 A1
ENTER V CHANGE* LY SERVICE - ENTER VALUE FACTOR AMPS PAR 901 Wood 298 270
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244
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FIGURE 24 Patent Application Publication Aug . 17 , 2017 Sheet 25 of 64 US 2017 / 0234117 A1
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FIGURE 25 Patent Application Publication Aug. 17, 2017 Sheet 26 of 64 US 2017 /0234117 A1
248 ENTERI
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FIGURE 26 Patent Application Publication Aug . 17 , 2017 Sheet 27 of 64 US 2017 / 0234117 A1
250
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FIGURE 27 Patent Application Publication Aug. 17, 2017 Sheet 28 of 64 US 2017 /0234117 A1
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FIGURE 28 Patent Application Publication Aug. 17, 2017 Sheet 29 of 64 US 2017 /0234117 A1
ht BACKDOOR
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THE FOLLOWING PARAMETERS CAN BE 336 VIEWED /CHANGED IN THE no BACKDOOR : PAR 699 - PAR 802 - PAR 803 - PAR 844 - PAR 103 " PAR 104 PAR 108 1 PÁR 112 - PAR 954 PAR 904 PAR 905 PAR 906 PAR 407 1 PAR 408 - PAR 412 PAR 451 PAR 423 1 PAR 424 if PAR 425 - PAR 426 it PAR 427 - PAR 428 PAR 429 $ PAR 430 - PAR 431 - PAR 432 - PAR 435 $ PAR 437 PAR 438 $- PAR 440 f Samarrenespa - PAR 441 $ PAR 443 PAR 444 $- PAR 446 . PAR 447 - PAR 449 1.- PAR 990 - PAR 991 - PAR 250
FIGURE 29 Patent Application Publication Aug. 17, 2017 Sheet 30 of 64 US 2017 /0234117 A1
p . . . DASED SET " TPM DRIVE CLEAR " TPM SPEED iyir. Licen cia SPEED REDUCED " BORDEN RUNNING REDUCED So v?i các ng h i và ti?n d?ng 364W oninginn KRAKKARA 338 3 stemmer FAULT POWER pom DRIVE WITH MODULE INCREASE OVER TEMPI TEMP > 115C SPEED BY 1 ,5 TOOOOOO VALD:1121 HZ PER MINUTE UNTIL 342 ORIGINAL NO SPEED A ROY . . 360 DECREASE POWER SPEED BY 12 kalimin Y ESreisimine apientesMODULE W HZ PER MINUTE WEMP > 113 .com ADOOOOOOOOO 344
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DRIVE RUNNING
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FIGURE 31 Patent Application Publication Aug. 17 , 2017 Sheet 32 of 64 US 2017 /0234117 A1
poco MOTOR START 376 388 RESET TIMER AND STARTUP COUNTER - YES SEQUENCE - NO SeminarsDONE stimin 378 pengetaschenCURRENT NO LIMITATION RESET TIMER ACTIVE AND 390 COUNTER INCREMENT TIMER 386 BAC Rinnai CLEAR WARNING IMERI SECS NO MOTOR SET JAM 392 RUNNING WARNING 396 nnin INCREMENT COUNTER 400 We 45.410J YCOUNTER ( 5 04 itter! YES 2 WIRE FAULT DRIVE 408 opowohnen WITH " JAM FAULT" mood REVERSE AND PULSE THE proovininin FORWARD THE MOTOR 3 doo MOTOR FOR 3 TIMES CYCLES 406
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FIGURE 33 Patent Application Publication Aug. 17, 2017 Sheet 34 of 64 US 2017 /0234117 A1
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FIGURE 34 Patent Application Publication Aug. 17, 2017 Sheet 35 of 64 US 2017 /0234117 A1
DRY RUN DETECTED ich 440 RESET NO LA COUNTERtunnetesserter 444 PAR 820 P inang 450 INCREMENT UPDATE RESET COUNTER FAULT LOG HVYOpom oci
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FIGURE 38 Patent Application Publication Aug. 17, 2017 Sheet 39 of 64 US 2017 /0234117 A1
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534 CLEAR RapidINTERNAL FAULT NO VOLTAGESMimice ARE > LA QUT OF RANGE on 536 Vol ves UPDATE 532 FAULT LOG
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INCREMENT Pi ty FAULT TIMER 540 Rex USER PRESSEDDeporte inter n asiona concouroktimes * FAULT W itprincipiosRESET 542 Besteha angan NO andwhite 20TIMER SECS NO odobno pupilamatan perhibeturintiems FAULT marathi .net CONDITION STILL Pooh THERE ? ickpit wordt N 546 FIGURE 40 Patent Application Publication Aug. 17, 2017 Sheet 41 of 64 US 2017 /0234117 A1
548 DRIVE IS POWERED
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FIGURE 41 Patent Application Publication Aug. 17, 2017 Sheet 42 of 64 US 2017 /0234117 A1
PD c an CONTROL
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FIGURE 44A Patent Application Publication Aug. 17, 2017 Sheet 45 of 64 US 2017 /0234117 A1
DRIVE IS POWERED SLONA 612 powe CLEAR e BUS Appen FAULT IN NO VOLTAGEtonton UPDATE DISPLAY BELOW FAULT LOG MIN ittiham Gaminiais 616 COASToctombo MOTOR TO STOPng 620 AND FAULT DRIVE WITH " UNDER VOLTAGE AUTO RESTART PENDING "
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FIGURE 46 Patent Application Publication Aug. 17, 2017 Sheet 47 of 64 US 2017 /0234117 A1
. . . 640 DRIVE Den Paso POWERED
642 PAR 920 EXTERNAL FAULT 644 DIGITAL VNPUThonen HIGH gorg picha EXTERNAL UPDATE V FAULT ACTIVE t FAULT LOG
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FIGURE 47 Patent Application Publication Aug. 17, 2017 Sheet 48 of 64 US 2017 /0234117 A1
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n i . . . pa CHANGE VALUE 670 672 PAR 913 K dari pintuYES tripte? -- - - NO LEDS S PSI PRESET : OFF SHOW STOPPED MAIN MENU : OFF SCREEN FAULT LOG : OFF STATUS : ON 674 PUMP OUT ON 676 STOP : OFF AUTO START : OFF G OODOOD WORD 678 680 ponopon . . . . . XX HZ SHOW STATUS A o ni . . . . XX. XX AMPS
SCREEN . RUNNING FIXED FREQ 682 R aporno L PUMP . | aprobareaOUT FIGURE 48 Sini . .. Patent Application Publication Aug. 17, 2017 Sheet 49 of 64 US 2017 /0234117 A1
684 PSI PRESET
686 presente IS THE KEY LOCKED ? Pored to YES
With . . 1688 toniiniint ERROR PRESS PASSWORD LEDS AN 690 PSI PRESET : ON MAIN MENU : OFF FAULT LOG : OFF STATUS : OFF PUMP OUT : UNCHANGED STOP UNCHANGED AUTO START : UNCHANGED ORO
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692 PRESET 1 PRESSURE ENTER CHANGE PAR 909 694
FIGURE 49 Patent Application Publication Aug. 17, 2017 Sheet 50 of 64 US 2017 /0234117 A1
696 MAIN MENU
t ipation
cons IS THE KEY LEDESMANCATATLOCKED ? YES 92 Aona posicionament ERROR PRESS Coccodd. tA vicini W AN. . . . The LEDS 700 IPSI PRESET : OFF MAIN MENU : ON FAULT LOG : OFF STATUS OFF PUMP OUT : UNCHANGED STOP : UNCHANGED AUTO START : UNCHANGED * * * * * * * *?????????????a * 704 T SHOW MAIN dopo
FIGURE 50 Patent Application Publication Aug. 17, 2017 Sheet 51 of 64 US 2017 /0234117 A1
706 woodce FAULT LOG
P 708 gadgovorLEDS oooooooooooooooo PSI PRESET : OFF MAIN MENU : OFF FAULT LOG : ON STATUS : OFF odococo PUMP OUT : UNCHANGED HANG HANGED
710 SOLDREN . . . . SHOW FAULT LOG
FIGURE 51 Patent Application Publication Aug. 17, 2017 Sheet 52 of 64 US 2017 /0234117 A1
ENTER 712
shtepiAULT LOG ACTIVE ? KA 714
S STOPPEDtipendicunt Li STATUS e SCREEN 2 716 ckintoties NO ERROR 720 INVALID KEY witpartureAS THE KEY Strin LOCKED ? ERROR We PRESS 724 PASSWORD arto MENU dettacaritatemOR w Promo Ni . 722 PARAMETER 2 MENU PARAMETER Strece opatwianie 728 t chine ENTER r WS havasiakastie 2ND LINE MENU YES Ad HIGHLIGHTED 2 a mecomicile SAVE VALUE - -NO AND CANCEL inay HIGHLIGHT Reitspo pMAY PARAMETER paNO NOT BE CHANGED programitWHILE RUNNING AND t YES DRIVE STOPPEDpot s a CHANGE WHILE nte intenant RUNNING ERROR Prostituttet! HIGHLIGHT 2ND LINE FIGURE 52 Patent Application Publication Aug. 17, 2017 Sheet 53 of 64 US 2017 /0234117 A1
738 BACK
740 watatheriaSTATUS RRRRRRR NO D SCREENinternet ? statements Suomi 744 742 igiving in consideration ERROR 2ND LINE that INVALID KEY porodiD HIGHLIGHTED 2 many W ROOM kinachoonitortechniston
746 CANCEL NEW 748 VALUE AND CANCEL 748 GO TO PARENT ) HIGHLIGHT GOTO MENU
FIGURE 53 Patent Application Publication Aug. 17, 2017 Sheet 54 of 64 US 2017 /0234117 A1
750. UP/ DOWN
752 nominat 2ND LINE ions, iting W HIGHLIGHTEDwidtieto 2 - YES 760 54 Diesongs CAN A MENU . . . RUNNING AUTO RicetteBE SCROLLED 2 YES Piev ieno Latit L INE FILLitting ? comportamieniami u deminimo dim RUN MANUAL . UNE FILL m 11111 oduled NO numberapped RI ERROR INVALID SCROLL MENU SCROLL
VALUEX . A . 764 762
FIGURE 54 Patent Application Publication Aug. 17, 2017 Sheet 55 of 64 US 2017 /0234117 A1
766 startto LEFT / RIGHT
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FIGURE 55 Patent Application Publication Aug. 17, 2017 Sheet 56 of 64 US 2017 /0234117 A1
robi PASSWORD 780 sentido em sortKEYS Smith NOCKED 2 YES, 786 ZOOM prehemiaeth accesitas STATUS LEDS PR POUR PSI PRESET : OFF MAIN MENU : OFF 784 FAULT LOG OFF STATUSBe . . OFF PUMP OUT : UNCHANGED STOP : UNCHANGED AUTO START : UNCHANGED b isontina more YES 786 H ERROR 23
ARASH. KEY LOCKED co USER 788 MANUALLY ENTERS THE PASSWORD SKA 790 PASSWORD CORRECT YES m 792 Dominicanmerti PARA SA UNLOCK THE ERROR LOCKABLE SOODSAAT INVALID KEYS wasan PASSWORD
794 SED STATUS FIGUREFIGURE SE 56 STaTus Patent Application Publication Aug. 17, 2017 Sheet 57 of 64 US 2017 /0234117 A1
796 LANGUAGE
edie XDDD 798 weiterhin IS THE KEY tomonidanLOCKEDJor ? ERROR T 800 INVALID Riceratodo PASSWORD eddodia DR W LEDS 802 PSI PRESET : OFF MAIN MENU : OFF FAULT LOG : OFF STATUS : OFF PUMP OUT : UNCHANGED STOP : UNCHANGED AUTO START : UNCHANGED DROOOOO00000 K
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FIGURE 57 Patent Application Publication Aug. 17, 2017 Sheet 58 of 64 US 2017 /0234117 A1
STATUS 808 D LEDS eco PSÍPRESET : OFF MAIN MENU : OFF FAULT LOG : OFF STATUS : ON PUMP OUT : UNCHANGED 810 STOP : UNCHANGEDA ADYANA 812 ht). IS AMP STATUS FirmaisiaSCREEN SHOWN - YES wi with minimalis the variant mo t i SHOW PS SHOW AMP STATUS !:. WATT STATUS SCREEN SCREEN 818 V odopie : ta *
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. AUTO START | XX HS XXXX AMPS XX AZ XXXX WATTS
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816 822 FIGURE 58 Patent Application Publication Aug. 17, 2017 Sheet 59 of 64 US 2017 /0234117 A1
826 STOP
PSI PRESET : OFF MAIN MENU : OFF 828 FAULT LOG : OFF RRRRRR STATUS : OFF PUN STOP : ON AUTO START : OFF 830 XX PSI 832 SHOW STOPPED hentaires et des contra SCREEN STOPPED
834 pipi HERE to STOP DRIVE STAROA soooooo
10 . Patent Application Publication Aug .17 , 2017 Sheet 60 of 64 US 2017/ 0234117 A1
336 AUTO START
LEDS ESPRESET : OFF
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84 RUN AUTO LINE FILL ???? * Tiangemoview 1 |
??? Patent Application Publication Aug. 17, 2017 Sheet 61 of 64 US 2017 /0234117 A1
846 FAULT RESET
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FIGURE 61 Patent Application Publication Aug. 17, 2017 Sheet 62 of 64 US 2017 /0234117 A1
856 862 868 FAULT ACTIVE FAULT ACTIVE TPM ACTIVE (RESTART (DRIVE (DRIVE STILL DRIVE PENDING ) STOPPED ) RUNNING ) POWERED UP pogoda
AMBER | RED FAULT RED FAULT WARNING ista GREEN LED LED BLINKS LED BLINKS LED LIGHTS LIGHTS UP UP K
858 864 870 876
SHOW SHOW SHOW "RESTART " DRIVE mind REASON PENDING " STOPPED " / FOR TPM 860 866 872
FIGURE 62A FIGURE 628 FIGURE 62C FIGURE 62D Patent Application Publication Aug . 17 , 2017 Sheet 63 of 64 US 2017 /0234117 A1
KEY KEY ERROR LOCKED 878 886
DISPLAY SHOWS: DISPLAY SHOWS : Key Error ! Error ! Invalid Key ! Press Password Key 880 888
H WAIT 0 . 9 . WAIT 0 . 9 SECONDS SECONDS 882 890 PREVIOUS PREVIOUS SCREEN IS SCREEN IS SHOWN SHOWN 884 892 FIGURE 63B
894 902 INVALID RUNNING PASSWORD ERROR
DISPLAYLAY SHOWS. : 896 DISPLAY SHOWS: Error ! Error ! Invalid Password ! Stop before editing COM
898 906 WAIT 0 . 9 WAIT 0 . 9 SECONDS SECONDS
900 011011101908 PREVIOUS PREVIOUS SCREEN IS SCREEN IS SHOWN SHOWN
FIGURE 630 FIGURE 63D Patent Application Publication Aug. 17, 2017 Sheet 64 of 64 US 2017 /0234117 A1
826 STOP
LEDS??????? ?????????????????????????????? PSI PRESET OFF ???????????? MAIN MENU OFF 828 FAULT LOG OF STATUS OFF ?????? PUMP OUT OFF ???? STOP ON AUTO START OFF wwwmasis
. win XX PSI SHOW www SCREEN ??????????? STOPPED ?????????????????????? XoMAALUMU ????????????????????????????????????????????????????????????????????????????? ???????????????????????????????????????????????????????????????
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FIGURE 59 US 2017 /0234117 A1 Aug . 17 , 2017
METHOD OF CONTROLLING A PUMP AND configured to , based on the monitored operating frequency , MOTOR cause the pump to temporarily boost the pressure in the fluid system to a temporary boost set point for a first timeperiod , RELATED APPLICATIONS where the temporary boost set point is programmable by a user using the directional buttons and the enter button . The [0001 ] This application is a continuation of U . S . patent variable frequency drive circuit is further configured to application Ser. No . 12 /481 , 435 , filed Jun . 9 , 2009 and titled determine whether the temporarily boosted pressure in the Method of Controlling a Pump and Motor , the entire con fluid system stays above the pressure set point for a second tents of which is incorporated herein by reference . time period and cause the pump to enter a sleep mode when the temporarily boosted pressure stays above the pressure set BACKGROUND point through the second time period . [0002 ] Submersible well pumps are connected to above ground drive systems that control the operation of the pump. DESCRIPTION OF THE DRAWINGS Some conventional pump controllers include only start [0006 ] FIG . 1 is a perspective view of a variable frequency capacitors and relays to turn the pump on and off based on drive according to one embodiment of the invention . system pressure . These pump controllers have limited capa 10007 FIG . 2 is a perspective view of the variable fre bilities with respect to pump control, safety, and customi quency drive of FIG . 1 with a cover removed . zation . Variable frequency drives (VFDs ) have also been 10008 ]. FIG . 3 is an interior view of the variable frequency used to control submersible well pumps but with limited drive of FIG . 1 . capabilities regarding user- friendly control and customiza [ 0009 ] FIG . 4 is a front view of a control pad of the tion . Conventional drives have also generally been designed variable frequency drive of FIG . 1 . for use with particular types ofmotors and often cannot be [0010 ) FIG . 5 is a schematic view of the variable fre used to retrofit motors that are already installed in the well, quency drive of FIG . 1 installed in a fluid system . especially two- wire, single -phase motors . [0011 ] FIG . 6 is a schematic illustration of the variable frequency drive of FIG . 1 . SUMMARY [0012 ] FIG . 7 is a flow chart illustrating a pump out [ 0003] Some embodiments of the invention can provide a operation . controller for a pump driven by a motor , where the pump is 10013 ] FIG . 8 is a flow chart illustrating an automatic line in fluid communication with a fluid system . The controller fill operation . includes a variable frequency drive circuit that controls [0014 ] FIG . 9 is a flow chart illustrating a manual line fill operation of the pump and a control panel connected to the operation . variable frequency drive circuit . The control panel can [ 0015 ] FIG . 10 is a flow chart illustrating a stop operation . include an automatic start button and a stop button . The [0016 ]. FIG . 11 is a flow chart illustrating a proportional / variable frequency drive circuit can automatically operate in integral/ derivative (PID ) mode control operation . a line fill mode when the pump starts when the automatic [0017 ] FIG . 12 is a flow chart illustrating a sleep mode start button is engaged and the pump can be disabled when operation . the stop button is engaged . [0018 ] FIG . 13 is a flow chart illustrating an alternate sleep [0004 ] According to some embodiments , a method of mode operation . controlling a pump driven by a motor with the pump in fluid [0019 ] FIG . 14 is a flow chart illustrating a digital input communication with a fluid system is provided . The method control operation . includes monitoring a pressure in the fluid system , moni [ 0020 ] FIG . 15 is a flow chart illustrating a relay output toring and adjusting an operating frequency of the motor to control operation . maintain the pressure at a pressure set point, and , based on [0021 ] FIG . 16 is a flow chart illustrating a main menu . the monitored operating frequency , causing the pump to 10022 ] FIG . 17 is a flow chart illustrating a settings menu . temporarily boost the pressure in the fluid system to a 0023 ] FIG . 18 is a flow chart illustrating a time parameter temporary boost set point for a first time period , where the menu . temporary boost set point is greater than the pressure set 10024 ] FIG . 19 is a flow chart illustrating a PID control point. The method also includes determining whether the parameter menu . temporarily boosted pressure in the fluid system stays above [0025 ) FIG . 20 is a flow chart illustrating a sleep param the pressure set point for a second time period and causing eter menu . the pump to enter a sleep mode when the temporarily [0026 ] FIG . 21 is a flow chart illustrating a password boosted pressure stays above the pressure set point through parameter menu . the second time period . [0027 ] FIG . 22 is a flow chart illustrating an external set [ 0005 ] According to some embodiments , a controller for a point parameter menu . pump driven by a motor is provided . The controller includes [0028 ] FIG . 23 is a flow chart illustrating a motor param a control panel with a display, directional buttons , and an eter menu . enter button , and a variable frequency drive circuit that 10029 ] FIG . 24 is a flow chart illustrating a sensor param controls operation of the pump. The variable frequency drive eter menu . circuit is connected to the control panel and is configured to [0030 ] FIG . 25 is a flow chart illustrating a pipe break monitor a pressure in the fluid system and monitor and adjust parameter menu . an operating frequency of the motor to maintain the pressure [0031 ] FIG . 26 is a flow chart illustrating a dry run at a pressure set point, where the pressure set point is parameter menu . programmable by a user using the directional buttons and [0032 ] FIG . 27 is a flow chart illustrating an input/ output the enter button . The variable frequency drive circuit is also parameter menu . US 2017 /0234117 A1 Aug . 17 , 2017
[0033 ] FIG . 28 is a flow chart illustrating a reset parameter [0065 ] FIG . 60 is a flow chart illustrating an automatic menu . start button control operation . [0034 ] FIG . 29 is a flow chart illustrating a backdoor 10066 ]. FIG . 61 is a flow chart illustrating a fault reset parameter menu . button control operation . [0035 ] FIG . 30 is a flow chart illustrating an overheat [0067 ] FIGS . 62A - 62D are flow charts illustrating LED prevention operation . indicator control operations . 00361. FIG . 31 is a flow chart illustrating an overcurrent 0068 ] FIGS. 63A -63D are flow charts illustrating error prevention operation . display control operations . [0037 ] FIG . 32 is a flow chart illustrating a jam prevention operation DETAILED DESCRIPTION [ 0038 ] FIG . 33 is a flow chart illustrating a pipe break prevention operation . [0069 ] Before any embodiments of the invention are [0039 ] FIG . 34 is a flow chart illustrating a dry run explained in detail, it is to be understood that the invention detection operation . is not limited in its application to the details of construction [0040 ] FIG . 35 is a flow chart illustrating a dry run fault and the arrangement of components set forth in the follow operation . ing description or illustrated in the following drawings. The invention is capable of other embodiments and of being [ 0041 ] FIG . 36 is a flow chart illustrating a jam fault practiced or of being carried out in various ways . Also , it is operation . to be understood that the phraseology and terminology used [0042 ] FIG . 37 is a flow chart illustrating an overtempera herein is for the purpose of description and should not be ture fault operation . regarded as limiting . The use of " including ," " comprising , " [0043 ] FIG . 38 is a flow chart illustrating an overcurrent or “ having " and variations thereof herein is meant to encom fault operation . pass the items listed thereafter and equivalents thereof as [ 0044 ] FIG . 39 is a flow chart illustrating an overvoltage well as additional items. Unless specified or limited other fault operation . wise , the terms “ mounted ," " connected ," " supported ,” and [ 0045 ] FIG . 40 is a flow chart illustrating an internal fault “ coupled ” and variations thereof are used broadly and operation . encompass both direct and indirect mountings , connections , 100461. FIG . 41 is a flow chart illustrating a ground fault supports , and couplings . Further, “ connected” and operation . " coupled ” are not restricted to physical or mechanical con [ 0047 ] FIG . 42 is a flow chart illustrating an open trans nections or couplings. ducer fault operation . [0070 ] The following discussion is presented to enable a [0048 ] FIG . 43 is a flow chart illustrating a shorted trans person skilled in the art to make and use embodiments of the ducer fault operation . invention . Various modifications to the illustrated embodi [0049 ] FIGS. 44A - 44B are flow charts illustrating a mul ments will be readily apparent to those skilled in the art, and tiple faults operation . the generic principles herein can be applied to other embodi [0050 ] FIG . 45 is a flow chart illustrating an undervoltage ments and applications without departing from embodi fault operation . ments of the invention . Thus, embodiments of the invention [0051 ] FIG . 46 is a flow chart illustrating a hardware fault are not intended to be limited to embodiments shown , but operation . are to be accorded the widest scope consistent with the [0052 ] FIG . 47 is a flow chart illustrating an external fault principles and features disclosed herein . The following operation detailed description is to be read with reference to the [0053 ] FIG . 48 is a flow chart illustrating a pump out figures , in which like elements in different figures have like button control operation . reference numerals . The figures , which are not necessarily to [0054 ] FIG . 49 is a flow chart illustrating a pressure preset scale , depict selected embodiments and are not intended to button control operation . limit the scope of embodiments of the invention . Skilled [0055 ] FIG . 50 is a flow chart illustrating a main menu artisans will recognize the examples provided herein have button control operation . many useful alternatives and fall within the scope of 100561. FIG . 51 is a flow chart illustrating a fault log button embodiments of the invention . control operation . [0071 ] FIG . 1 illustrates a variable frequency drive (VFD , [0057 ] FIG . 52 is a flow chart illustrating an enter button hereinafter “ the drive " ) 10 according to one embodiment of control operation . the invention . In some embodiments, the drive 10 can be [0058 ] FIG . 53 is a flow chart illustrating a back button used to control the operation of an AC induction motor 11 control operation . that drives a water pump 12 ( as shown in FIG . 5 ) . The drive [ 0059 ] FIG . 54 is a flow chart illustrating an up/ down 10 can be used in a residential , commercial, or industrial button control operation . pump system to maintain a substantially constant pressure . [0060 ] FIG . 55 is a flow chart illustrating a left / right The motor 11 and pump 12 can be a submersible type or an button control operation . above - ground type . The drive 10 can monitor certain oper [0061 ] FIG . 56 is a flow chart illustrating a password ating parameters and control the operation of the motor 11 button control operation . in response to the sensed conditions. [0062 ] FIG . 57 is a flow chart illustrating a language 10072 ] As shown in FIGS . 1 and 2 , the drive 10 can button control operation . include an enclosure 13 and a control pad 14 . The enclosure [0063 ] FIG . 58 is a flow chart illustrating a status button 13 can be a NEMA 1 indoor enclosure or a NEMA 3R control operation . outdoor enclosure. In one embodiment, the enclosure 13 can [ 0064 ] FIG . 59 is a flow chart illustrating a stop button have a width of about 9 . 25 inches , a height of about 17 . 5 control operation . inches, and a depth of about 6 . 0 inches. The enclosure 13 can US 2017 /0234117 A1 Aug . 17 , 2017 include a keyhole mount 16 for fast and easy installation the output power terminal block 32 can be removable and onto a wall, such as a basement wall. The enclosure 13 can replaceable without replacing the drive circuit board or the include slots 18 through which air that cools the drive 10 can entire drive 10 . pass out of the enclosure 13. The control pad 14 can be [0077 ] As shown in FIGS. 1- 4 , a control pad 14 of the positioned within the enclosure 13 for access through a drive 10 can include a backlit liquid crystal display 36 and rectangular aperture 20 . several control buttons 38 . As shown in FIG . 4 , the control [0073 ] As shown in FIG . 2 , the enclosure 13 can include buttons 38 can include a pump - out button 40 , a pressure a removable cover 22 with attached side panels . Removing preset button 42 , a main menu button 44 , and a fault log the cover 22 allows access to a wiring area 24 , which is button 46 . The control buttons 38 can also include a keypad located adjacent to a bottom panel 25 of the enclosure 13 lockout button 48 and a language button 50 . The control pad with several conduit holes 26 . As shown in FIGS . 2 and 3 , 14 can include several directional buttons 52 , a back button the wiring area 24 is free of any electrical components or 54 , and an enter button 56 . The control pad 14 can further printed circuit board material that may impede any wiring . include a status button 58 , a stop button 60 , an automatic The wiring area 24 can provide access to an input power start button 62 , and a fault reset button 64 . Finally , the terminal block 28 , input /output ( I/ O ) spring terminals 30 , control pad 14 can include light emitting diode ( LED ) and an output power terminal block 32 . Each one of the indicators 66 , to indicate a status of the drive 10 , such as an conduit holes 26 can be aligned with one of the input power ON LED 68 , a Warning LED 70 , and a Fault LED 72 . terminal block 28 , the I / O spring terminals 30 , and the [0078 ] As shown in FIGS. 2 and 3 , the drive 10 can output power terminal block 32 . In addition , in some include an electromagnetic interference (EMI ) filter 74 . The embodiments , the I/ O spring terminals 30 can include digital EMI filter 74 can reduce electrical noise generated by the output terminals 30A , digital input terminals 30B , I/ O power motor 11 , especially noise that interferes with AM radio supply terminals 30C , and analog input terminals 30D . stations. The drive 10 can reduce electrical noise while [0074 ] The wiring area 24 can include a wiring space 34 simultaneously being compatible with a Ground Fault Cir between the bottom panel 25 and the input power terminal cuit Interrupter (GFCI ) . An unintentional electric path block 28 , the I/ O spring terminals 30 , and the output power between a source of current and a grounded surface is terminal block 32 . The wiring space 34 can be between generally referred to as a " ground fault. ” Ground faults about three inches and about six inches in height in order to occur when current is leaking somewhere , and in effect , allow enough room for an installer to access the input power electricity is escaping to the ground . terminal block 28 , the I / O spring terminals 30 , and the [0079 ] The drive 10 can be compatible with a number of output power terminal block 32 . different types of motors 11 , including , but not limited to , [0075 ] The input power terminal block 28 , 1 /0 spring AC induction motors that are two -wire permanent split terminals 30 , and the output power terminal block 32 can be capacitor (PSC ) single - phase motors ; three -wire single used to control the motor 11 and to provide output infor phase motors ; or three - phase motors . The drive 10 can be mation in any number of configurations and applications. connected to a previously - installed motor 11 in order to Various types of inputs can be provided to the drive 10 to be retrofit the controls for the motor 11 . If the motor is a processed and used to control the motor 11 . The analog input single - phase motor , the installer can use the control pad 14 terminals 30D can receive analog inputs and the digital input to select either two -wire or three - wire . For a three -wire terminals 30B can receive digital inputs . For example , any motor 11 , the drive 10 can automatically generate a first suitable type of run / enable switch can be provided as an waveform and a second waveform with the second wave input to the drive 10 ( e . g ., via the digital input terminals form having a phase angle of about 90 degrees offset from 30B ) . The run / enable switch can be part of a lawn irrigation the first waveform . In addition , the controller 75 (as shown system , a spa pump controller , a pool pump controller, a float in FIG . 6 ) can automatically set a minimum and maximum switch , or a clock /timer . In some embodiments , the digital frequency allowance for the motor 11 depending on the input terminals 30B can accept a variety of input voltages , selection . such as voltages ranging from about 12 volts to about 240 [0080 ] The drive 10 can be programmed to operate after a volts , direct current (DC ) or alternating current ( AC ) . simple start - up process by a user using the control pad 14 . [0076 ] The digital output terminals 30A can connect to The start- up process can be a five - step process for a single digital outputs , such as relay outputs . Any suitable type of phase motor 11 and a four -step process for a three -phase indicator device , status output, or fault alarm output can motor 11 . The start - up process for a single - phase motor 11 serve as a digital, or relay , output ( e . g ., be connected to the can include ( 1 ) entering a service factor current value , ( 2 ) digital output terminals 30A ) . A status output can be used to selecting either a two -wire motor or a three -wire motor, ( 3 ) control a second pump , for example , to run the second pump entering a current time, (4 ) entering a current date , and (5 ) when the pump 12 is running . A fault alarm output can , for engaging the pump- out button 40 or the automatic start example , place a call using a pre - defined phone number , button 62 . The start - up process for a three - phase motor 11 signal a residential alarm system , and / or shut down the can include ( 1 ) entering a service factor current value , ( 2 ) pump 12 when a fault is determined . For example , when entering a current time, ( 3 ) entering a current date , and ( 4 ) there is a pipe break fault (as described below with reference engaging the pump -out button 40 or the automatic start to FIG . 33 ) , the digital output terminals 30A can energize a button 62 . relay output, causing the pre -defined phone number to be [0081 ] The pump- out button 40 can be used to enter the automatically dialed . The input power terminal block 28 , the drive 10 in a pump outmode to clean out sand and dirt from 1 / 0 spring terminals 30 , and the output power terminal block a newly - dug well . The pump -out button 40 can be engaged 32 can all be coupled to a drive circuit board (not shown ), once the pump 12 is installed in the new well and once the for connection to a controller 75 (as shown in FIG . 6 ) of the drive 10 is connected to the motor 11 . The pump - out mode drive 10 . Further , the input power terminal block 28 and /or can provide an open discharge of sand and dirt from the well, US 2017 /0234117 A1 Aug . 17 , 2017 for example , onto a lawn . In one embodiment, the drive 10 [0086 ] FIGS. 7 -15 are flow charts describing pump control can operate the pump 12 in the pump out mode at about 45 according to some embodiments of the invention . The flow Hertz (Hz ) . The pump out mode operation is further chart of FIG . 7 illustrates when the controller 75 receives a described below with respect to FIG . 7, and a pump -out signal to run the pump in the pump out mode 76 ( e .g ., when button control operation is further described below with the pump- out button 40 is pressed ). The controller 75 first respect to FIG . 48 . determines, at step 78 , if the pump is already running in [0082 ] The controller 75 can include software executed by pump out mode. If so , the pump is being run at a correct , a digital signal processor (DSP , as shown in FIG . 6 ) or a fixed frequency for pump out mode (step 80 ) . If not, the microprocessor and can perform real- time control including controller 75 , at step 82 , ramps up the input frequency of soft - start, speed regulation , and motor protection . The drive power to the motor 11 to the correct frequency , then pro 10 can be controlled to maintain substantially constant water ceeds to step 80 . pressure in a water system that may or may not utilize a tank . 10087 ] FIG . 8 illustrates an automatic line fill operation To achieve this , the controller 75 can implement a classical 84 , according to some embodiments . This operation can Proportional/ Integral/ Derivative ( PID ) method using pres automatically run at drive start- up ( e . g ., when the drive 10 sure error as an input. Pressure error can be calculated by is powered up , after a power interruption , when themotor 11 subtracting an actual water pressure from the desired water is restarted , or when the automatic start button 62 is pressure ( i. e . , a pressure set point) . An updated speed control pressed ) . Thus , the motor may be off ( i . e . , at 0 Hz) at the command can then be generated by multiplying the pressure beginning of this operation . The controller 75 first can ramp error by a proportional gain , multiplying the integral of the up the frequency driving the motor from 0 Hz to about 45 Hz pressure error by an integral gain , multiplying the derivative in less than a first time period , such as about two seconds of the pressure error by a derivative gain , and summing the ( step 86 ) . In a second time period , such as about two results . Thus , the controller 75 can increase or decrease the minutes , or about five minutes in some embodiments , the speed of the motor 11 to maintain a constant pressure set controller 75 can start to ramp up the frequency from , for point. The PID mode is further described below with respect example , about 45 Hz to about 55 Hz ( step 88 ). During the to FIG . 11 . second time period , the controller 75 determines the pres [ 0083 ] The controller 75 can determine the actual water sure via input from the pressure transducer 15 ( step 90 ). If pressure value from an electronic pressure transducer 15 the sensed pressure has reached a minimum pressure , or ( e . g . , in communication with the controller 75 via the analog pressure set point (e .g . , about 10 PSI) , indicating the line has input terminals 30D ). In some embodiments , as shown in been filled , the fill operation is completed and the controller FIG . 5 , the pressure transducer 15 can be located near a 75 enters PID mode ( step 92 ). However , if the sensed pressure tank 17 fluidly coupled to the pump 12 . pressure is less than 10 PSI at step 90 , the controller 75 [0084 ] If motor 11 is off ( i . e . , not being driven ) , water determines if the second time period ( e . g ., about two min pressure can still be monitored , but no actions are taken until utes or about five minutes ) has passed ( step 94 ) . If the the pressure falls below a certain value ( e . g ., a low band second period has not passed , the controller 75 reverts back pressure value ) . If the water pressure falls below the low to step 88 and continues to ramp the motor frequency . If the band pressure , the controller 75 can restart the motor 11 . In second time period has passed , the controller 75 will hold some embodiments , the low band pressure can be set , or the frequency at about 55 Hz for about one minute ( step 96 ) . defaulted , to 1 - 10 pounds per square inch (PSI ) lower than The controller 75 then determines if the sensed pressure is the pressure set point. Once the motor 11 is restarted , normal about 10 PSI ( step 98 ) . If the sensed pressure is about 10 operation with PID control ( i. e ., PID mode ) can commence . PSI, indicating the line has been filled , the fill operation is In one embodiment, one of two conditions can trigger the completed and the controller 75 enters PID mode ( step 92 ). controller 75 to turn the motor 11 off . A first condition can However, if the sensed pressure is still less than 10 PSI at be if a sleep mode (described with respect to FIG . 12 ) is step 90 , the controller 75 determines if one minute has triggered . A second condition can be if the pressure exceeds passed ( step 100 ) . If one minute has not passed , the con a certain safety value ( i . e . , about 20 PSI above the pressure troller 75 reverts back to step 96 . If one minute has passed , set point ) . Other conditions that can stop the drive 10 are a dry run fault is recognized and a dry run fault operation is various faults (described further below ) , the user pressing executed ( step 102 ) ( e . g . , the system is stopped ) . the stop button 60 , and lack of a digital input for an optional [0088 ] In one alternative embodiment, step 88 can include run enable mode. setting the frequency to about 45 Hz for the second time [0085 ] For normal operation , with the motor 11 being period , and if the sensed pressure is less than 10 PSI after the driven , the controller 75 can regulate pump speed in a second time period , repeating step 88 with the frequency set continuous fashion using PID control as long as the pressure to about 50 Hz for another second time period . If the sensed remains below the safety pressure value, such as about 20 pressure is still less than 10 PSI after the second time period PSI above the pressure set point. The drive 10 can stop the while at 50 Hz, step 88 can be repeated with the frequency motor 11 whenever the actual pressure exceeds the safety set to about 55 Hz for yet another second time period . If the pressure value. During normal operation , as long as water sensed pressure is still less than 10 PSI after the second time usage does not exceed the motor /pump capabilities , the period while at 55 Hz, the controller 75 can continue to step pressure can remain constant at approximately the pressure 96 . set point. Large instantaneous changes in flow requirements [0089 ] FIG . 9 illustrates a manual line fill operation 104 , can result in variations from the desired pressure band . For according to some embodiments . The motor 11 is run at a example , if flow is stopped , causing the pressure to quickly manually - controlled frequency ( e . g . , entered by a user ) at increase , the motor 11 can be stopped ( i . e . , set to 0 Hz ). This step 106 . The motor 11 keeps running at this frequency until can be considered an alternate sleep mode operation and is the sensed pressure reaches about 10 PSI (step 108 ). Once further described below with respect to FIG . 13 . the sensed pressure has reached about 10 PSI, the controller US 2017 /0234117 A1 Aug . 17 , 2017
75 enters PID mode ( step 110 ). In some embodiments , if the indicating no flow , the controller 75 then determines if the controller 75 does not enter PID mode within a time period pressure is above the pressure set point ( step 148 ) . If not, the ( e . g . , fifteen minutes ) , the drive 10 is stopped . controller 75 reverts back to step 126 . If the pressure is [0090 ] The manual fill line operation can be considered above the pressure set point, the pump enters the sleep mode always enabled because it can be executed at any time causing the motor frequency to coast down to 0 Hz (step during the auto line fill operation . For example , by using the 150 ) and a “ sleep mode active ” message to be displayed on up and down directional buttons 52 on the control pad 14 , the liquid crystal display 36 ( step 152 ) . While in sleep mode , the user can interrupt the automatic line fill operation and at step 154 , the controller 75 continuously determines if the adjust the frequency output to the motor 11 , thus changing pressure stays above a wakeup differential pressure (e . g. , the motor speed . Once in manual line fill mode , the user can about 5 PSI below the pressure set point ). If the pressure continue to change the speed as needed at any time. The drops below the wakeup differential pressure, the controller motor 10 can continue at the new set frequency until the 75 reverts back to step 126 . sensed pressure reaches about 10 PSI, and then it will [0095 ] In some embodiments , the controller 75 will only proceed to PID mode , as described above . The manual fill proceed from step 126 to step 128 if the pressure has been line operation can be beneficial for both vertical or horizon stable for at least a minimum time period ( e . g . , one or two tal pipe fill applications. In addition , both the automatic fill minutes) . Also , when the controller 75 cycles from step 128 line operation and the manual fill line operation can prevent to step 130 and back to step 126 , the controller 75 can wait common motor issues seen in conventional systems, such as a time period ( e . g ., one or two minutes ) before again motor overloading and the occurrence of water hammering . proceeding to step 128 . In some embodiments , the controller [0091 ] FIG . 10 illustrates a stop operation 112 , according 75 can determine if the motor speed is stable at step 128 . In to some embodiments . The controller 75 determines if the addition , the controller 75 can perform some steps of FIGS . pump is running (step 114 ) . If the pump is not running ( e . g . , 11 and 12 simultaneously . if the drive 10 is in sleep mode or a run enable command is 0096 ] By using the sleep mode operation , a separate not triggered ), the drive 10 is stopped ( step 116 ) . If the pump device does not need to be purchased for the drive 10 ( e . g . , is running , the motor is allowed to coast to a stop ( i . e . , 0 Hz) a flow meter ). Further , the sleep mode operation can self at step 118 , then proceeds to step 116 . adjust for changes in pump performance or changes in the [ 0092 ] FIG . 11 illustrates a PID mode operation 120 , pumping system . For example , well pump systems often according to some embodiments . The controller 75 continu have changes in the depth of the water in the well both due ously determines if the pressure is at a programmed set point to drawdown as well as due to time of year or drought ( step 122 ) . If the pressure is not at the programmed set point, conditions . The sleep mode operation can be executed PID feedback control is used to ramp the frequency until the independent of such changes. In addition , the sleep mode pressure reaches the set point (step 124 ) . operation does not require speed conditions specific to the 10093 ] FIG . 12 illustrates the controller 75 , running in PID pump being used . mode ( at step 126 ) , checking if the pump should enter a [ 0097 ] FIG . 13 illustrates the controller 75, running in PID sleep mode . First , at step 128, the controller 75 determines mode , checking if the pump should enter an alternate sleep if the frequency of the motor 11 is stable within about + / - 3 mode 156 . First , at step 158 , the controller 75 determines if Hz (e .g . , at a steady -state frequency ). If not ( step 130 ), a pressure is at a preset value above the pressure set point boost delay timer is reset and the controller 75 reverts to step ( e . g ., 20 PSI above the pressure set point) . If not ( step 160 ) , 126 . If the frequency of the motor 11 is stable , the boost a timer is reset and the controller 75 reverts to step 156 . If delay timer is incremented at step 132 . If, at step 134 the the pressure is 20 PSI above the pressure set point, the timer boost delay timer is not expired after being incremented , the is incremented at step 162 . If , at step 164 the timer is less controller 75 reverts back to step 126 . However , if , at step than a value , such as 0 . 5 seconds , the controller 75 reverts 134 the boost delay timer has expired , the controller 75 back to step 156 . However, if , at step 164 the timer has proceeds to step 136 and the pressure is boosted ( e . g ., about exceeded 0 . 5 seconds, the controller 75 proceeds to step 166 3 PSI above the pressure set point) for a short period of time and the timer is reset . The controller 75 then sets the motor ( e . g . , about 15 seconds or about 30 seconds ) . frequency to 0 Hz ( step 168 ) and displays a " sleep mode [0094 ] Until the short period of time has passed ( step 138 ) , active ” message 170 on the liquid crystal display 36 . The the controller 75 determines if the pressure stays between controller 75 then again increments the timer ( step 172 ) until the pressure set point ( e . g ., about 10 PSI) and the boosted the time reaches another value , such as 1 minute ( step 174 ) , pressure (step 140 ) . If, in that short period of time, the and then proceeds to step 176 . At step 176 , the controller 75 pressure falls outside ( i. e ., below ) the range between the keeps the motor frequency at 0 Hz and displays a “ sleep pressure set point and the boosted pressure , the controller 75 mode active” message 178 on the liquid crystal display 36 reverts back to step 126 . If , however, the pressure stays as long as the pressure is above a wakeup differential between the pressure set point and the boosted pressure , the pressure ( step 180 ). If the pressure drops below the wakeup controller 75 then decrements the pressure over another differential pressure ( e . g . , water is being used ) , the controller short period of time ( step 142 ) . Until the short period of time 75 reverts back to step 156 . has passed ( step 144 ) , the controller 75 determines if the [ 0098 ] FIG . 14 illustrates an example of controller opera pressure stays between the pressure set point ( e . g . , the tion using the digital input. The controller 75 first recognizes steady - state pressure ) and the boosted pressure ( step 146 ) . a digital input (step 182 ) . If an external input parameter is If, in that short period of time, the pressure falls outside the unused ( step 184 ) , the controller 75 takes no action whether range between the pressure set point and the boosted pres the input is high or low ( steps 186 and 188 , respectively ) . If suresu , indicating that there is flow occurring , the controller 75 the external input parameter is set to a run enabled mode reverts back to step 126 . If, however, the pressure stays (step 190 ) and the input is high ( e . g ., indicating allowing the between the pressure set point and the boosted pressure , drive 10 to be run ) , the controller 75 determines if the drive US 2017 /0234117 A1 Aug . 17 , 2017
10 is running (step 192 ). If the drive 10 is running , the the settings menu 240 to view the following parameters , as controller 75 can take no action ( step 196 ) and continue in shown in FIG . 17 : time 254 , PID control 256 , sleep 258 , its current mode of operation . If the drive 10 is not running , password 260 , and external set point 262. the controller 75 can start an auto line fill operation ( step 194 ), as described with reference to FIG . 8 (e . g ., similar to [0102 ] FIG . 18 illustrates the user' s options after selecting actions taken if the auto start button 62 is pressed ) . If the the time parameter 254 from the settings menu 240 . The user external input parameter is set to a run enabled mode ( step can toggle up and down between setting a current hour 264 190 ) and the input is low ( e . g . , indicating to stop the drive or a date 266 . If the user selects the hour parameter 264 , the 10 ) , the controller 75 can check if the drive 10 is stopped user can enter a current time 268 , and a time value for the ( step 198 ) . If the drive 10 is not stopped , the controller 75 controller 75 will be changed according to the user ' s input can execute a stop operation ( step 200 ) , as described with 270 . If the user selects the date parameter 266 , the user can reference to FIG . 10 . If the drive 10 is stopped , the controller enter a current date 272 and a date value for the controller 75 can take no action ( step 202 ) . If the external input 75 will be changed according to the user ' s input 270 . parameter is set to an external fault mode (step 204 ) and the [0103 ] FIG . 19 illustrates the user ' s options after selecting input is high ( e . g . , indicating an external fault ) , the control the PID control parameter 256 from the settings menu 240 . ler 75 can perform an external fault operation ( step 206 ) , as The following parameters can be chosen after selecting PID described with reference to FIG . 47. If the external input control 256 : proportional gain 274 , integral time 276 , parameter is set to an external fault mode ( step 204 ) and the derivative time 278 , derivative limit 280 , and restore to input is low ( e . g . , indicating there is no external fault ) , the defaults 282 . The user can select any of the parameters controller 75 can clear any external fault indications ( step 274 - 282 to modify one or more preferences associated with 208 ) . If the external input parameter is set to an external set the parameters , and appropriate values for the controller 75 pointmode (step 210 ) and the input is high , the controller 75 will be changed 270 . sets the PID set point to “ external” ( step 212 ), for example , [0104 ] FIG . 20 illustrates the user 's options after selecting so that the digital input controls the pressure set point for the sleep parameter 258 from the settings menu 240 . The PID pressure control. If the external input parameter is set to following parameters can be chosen after selecting sleep an external set point mode (step 210 ) and the input is low , 258 : boost differential 284 , boost delay 286 , wakeup differ the controller 75 sets the PID set point to “ normal” ( step ential 288 , and restore to defaults 290 . The user can select 214 ) , for example , so that the digital input has no control any of the parameters 284 - 290 to modify one or more over the pressure set point for PID pressure control. preferences associated with the parameters , and appropriate [0099 ] FIG . 15 illustrates controller operation of a relay values for the controller 75 will be changed 270 . The output. When the drive 10 is powered ( step 216 ), the parameters can be set to modify or adjust the sleep mode controller 75 determines if a relay output parameter is operation described with reference to FIG . 12 . unused ( step 218 ) . If so , the controller 75 turns the relay off [0105 ] FIG . 21 illustrates the user 's options after selecting ( step 220 ) . If not, the controller 75 determines if the relay the password parameter 260 from the settings menu 240 . output parameter is set to a run mode ( step 222 ). If the relay The following parameters can be chosen after selecting output parameter is set to a run mode (at step 222 ) , the controller 75 determines if the drive 10 is running ( step 224 ) . password 260 : password timeout 292 and password 294 . The The controller 75 will then turn the relay off if the drive 10 user can select any of the parameters 292 - 294 to modify one is not running (step 226 ) or turn the relay on if the drive 10 or more preferences associated with the parameters, and is running ( step 228 ) . If the relay output parameter is not set appropriate values for the controller 75 will be changed 270 . to a run mode (at step 222 ), the controller 75 determines if The password timeout parameter 292 can include a timeout the relay output parameter is set to a fault mode ( step 230 ). period value . If the control pad 14 is not accessed within the If so , the controller 75 determines , at step 232 , if the drive set timeout period , the controller 75 175 can automatically 10 is tripped ( e . g ., a fault has occurred and the drive 10 has lock the control pad 14 (i . e . , enter a password protection been stopped ). The controller 75 will then turn the relay off mode ) . To unlock the keys, or leave the password protection if the drive 10 has not been tripped (step 234 ) or turn the mode , the user must enter the password that is set under the relay on if the drive 10 has been tripped (step 236 ) . For password parameter 294 . This is further described below example , if an alarm is the relay output, the alarm can be with reference to FIG . 56 . activated if the drive 10 has been tripped to indicate the fault [0106 ] FIG . 22 illustrates the user 's options after selecting condition to the user. the external set point parameter 262 from the settings menu [0100 ] FIGS. 16 -29 are flow charts describing menu 240 . The user can select the external set point parameter 296 operations according to some embodiments of the invention . to modify one or more preferences associated with the FIG . 16 illustrates a main menu 238 of the controller 75 . The parameter 296 , and appropriate values for the controller 75 main menu 238 can include the following parameters : will be changed 270 . settings menu 240 , motor 242 , sensor 244 , pipe break 246 , [0107 ] FIG . 23 illustrates the user' s options after selecting dry run 248 , I/ O ( input/ output ) 250 , and reset to defaults the motor parameter 242 from the main menu 238 . The 252. The user can view the main menu 238 on the liquid following parameters can be chosen after selecting motor crystal display 36 using the main menu button 44 on the 242 : service factor amps 298 , connection type 300 , mini control pad 14 . The user can then toggle up and down mum frequency 302 , maximum frequency 304 , and restore through the parameters of the main menu 238 using the to defaults 306 . The connection type parameter 300 may directional buttons 52 . The user can select a parameter using only be available if the drive 10 is being used to run a the enter button 56 . single - phase motor. If the drive 10 is being used to run a 10101 ] From the main menu 238 , the user can select the three - phase motor, the connection type parameter 300 may settings menu 240 . The user can toggle up and down through not be provided . The user can select any of the parameters US 2017 /0234117 A1 Aug . 17 , 2017
298 - 306 to modify one or more preferences associated with ( e . g . , 115 degrees Celsius ). If so , an overheat fault operation the parameters , and appropriate values for the controller 75 is executed ( step 342 ) . If not, the controller 75 then deter will be changed 270 . mines , at step 344 , if the power module temperature is [0108 ] FIG . 24 illustrates the user ' s options after selecting greater than a second temperature ( e . g . , about 113 degrees the sensor parameter 244 from the main menu 238 . The Celsius ) . If so , the controller 75 , at step 346 , decreases the following parameters can be chosen after selecting sensor speed of the motor by a first value ( e . g . , about 12 Hz per 244 : minimum pressure 308 , maximum pressure 310 , and minute ) and continues to step 348 . If not, the controller 75 restore to defaults 312 . The user can select any of the then determines, at step 350 , if the power module tempera parameters 308 - 312 to modify one or more preferences ture is greater than a third temperature ( e . g . , about 110 associated with the parameters, and appropriate values for degrees Celsius) . If so , the controller 75 , at step 352, the controller 75 will be changed 270 . decreases the speed of the motor by a second value ( e . g . , [0109 ] FIG . 25 illustrates the user ' s options after selecting about 6 Hz per minute ) and continues to step 348 . If not, the the pipe break parameter 246 from the main menu 238 . The controller 75 then determines, at step 354 , if the power following parameters can be chosen after selecting pipe module temperature is greater than a fourth temperature break 246 : enable pipe break detection 314 and number of ( e . g . , about 105 degrees Celsius ) . If so , the controller 75 , at days without sleep 316 . The user can select either of the step 356 , decreases the speed of the motor by a third value parameters 314 - 316 to modify one or more preferences ( e . g . , about 3 Hz per minute ) and continues to step 348 . If associated with the parameters , and appropriate values for not , the controller 75 proceeds to step 348 . At step 348 , the the controller 75 will be changed 270 . In some embodi controller 75 determines if the speed has been reduced ( i. e . , ments , the number of days without sleep parameter 316 can if the controller 75 performed steps 346 , 352 , or 356 ) . If so , include values in the range of about four hours to about the controller 75 , at step 358 , determines if the power fourteen days. The enable pipe break detection parameter module temperature is less than a fifth value ( e . g ., about 95 314 can allow the user to enable or disable pipe break degrees Celsius ). If the power module temperature is less detection . than the fifth value , then the controller 75 increases the [0110 ] FIG . 26 illustrates the user' s options after selecting speed of the motor by a fourth value ( e . g ., about 1 . 5 Hz per the dry run parameter 248 from the main menu 238 . The minute ) until the motor ' s original speed is reached ( step following parameters can be chosen after selecting dry run 360 ) and a warning message “ TPM : Speed Reduced ” is 248 : auto reset delay 318 , number of resets 320 , and reset displayed (step 362 ). If the power module temperature is window 322 . The user can select either of the parameters greater than the fifth value, the controller 75 proceeds 318 - 320 to modify one or more preferences associated with straight to step 362. From step 362 , the controller 75 reverts the parameters , and appropriate values for the controller 75 back to step 338 , and repeats the above process. If, at step will be changed 270 . The user can select the reset window 348 , the controller 75 determines that the speed has not been parameter 322 to view a value 324 indicating a reset window reduced ( i . e . , the controller 75 did not performed steps 346 , of the controller 75 . The reset window value can be based 352 , or 356 ) , then the “ TPM : Speed Reduced ” warning from the values chosen for the auto reset delay 318 and the message is cleared ( step 364 ) , the controller 75 reverts back number of resets 320 . Thus , the reset window parameter 322 to step 338 , and the above operation is repeated . In some can be a view - only ( i . e . , non - adjustable ) parameter. embodiments , the power module being monitored can be the [ 0111 ] FIG . 27 illustrates the user' s options after selecting drive 10 itself or various components of the drive 10 ( e. g ., the 1 / 0 parameter 250 from the main menu 238 . The a heat sink of the controller 75 , the motor 11 , or the pump following parameters can be chosen after selecting I/ O 250 : 12 ) . external input 326 and relay output 328 . The user can select [0115 ] FIG . 31 illustrates an overcurrent prevention opera either of the parameters 326 - 328 to modify one or more tion of the controller 75 . When the drive 10 is running ( step preferences associated with the parameters , and appropriate 366 ) , the controller 75 determines , at step 368 , if the drive values for the controller 75 will be changed 270 . current is being limited ( e . g ., because it is above the refer [ 0112 ] FIG . 28 illustrates the user ' s options after selecting ence service factor amps parameter 298 in FIG . 23 ). If so , a the reset to defaults parameter 252 from the main menu 238 . warning message " TPM : Service Amps ” is displayed ( step The user can select the parameter 330 to change all values 370 ) and the Warning LED 70 is illuminated (step 372 ) . The to factory default values 270 . controller 75 then reverts back to step 366 where the [0113 ] FIG . 29 illustrates a backdoor parameter 332 , operation is repeated . If the drive current is not being according to some embodiments . With the backdoor param limited , the “ TPM : Service Amps” warning message and the eter 332 , the user can choose a parameter 334 not normally Warning LED 70 are cleared ( step 374 ). accessible through other menus . The user can select the [0116 ] FIG . 32 illustrates a jam prevention operation of parameter 334 to modify one or more preferences associated the controller 75 . When the motor is triggered to start ( step with the parameter , and appropriate values for the controller 376 ), the controller 75 determines, at step 378 , if a startup 75 will be changed 270 . The parameter 334 that the user sequence is completed . If so , a timer and a counter are reset selects can be from a list of parameters 336 . The list of ( step 380 ) , any warning messages are cleared (step 382 ) , and parameters 336 can include one or more of the parameters the motor is operating ( step 384 ) . If the startup sequence is disclosed above as well as other parameters . not completed at step 378 , then the controller 75 proceeds to [0114 ] FIGS. 30 - 47 are flow charts describing drive warn step 386 to check if current limitation is active . If not, the ings and faults according to some embodiments of the timer and the counter can be reset ( step 388 ) , and the invention . FIG . 30 illustrates an overheat prevention opera controller 75 can proceed back to step 376 . If the controller tion of the controller 75 . When the drive 10 is running ( step 75 detects that current limitation is active at step 386 , then 338 ) , the controller 75 first determines , at step 340 , if a the timer is incremented ( step 390 ) . If the timer has not power module temperature is greater than a first temperature reached five seconds , at step 392 , the controller 75 reverts US 2017 /0234117 A1 Aug . 17 , 2017 back to step 376 . However, if the timer has reached five Restart Pending " fault message ( step 454 ) , then start a fault seconds, at step 392 , the controller 75 proceeds to step 396 . timer ( step 456 ) , and continuously check if the user has The controller 75 sets a jam warning ( step 396 ) and incre pressed the fault reset button 64 ( step 458 ) or if a timer has ments the counter ( step 398 ) . If the counter is greater than exceeded a time value ( step 460 ) . The time value can be the five, at step 400 , the controller 75 executes a jam fault auto reset delay parameter 318 ( shown in FIG . 26 ) set by the operation ( step 402 ) . If the counter is not greater than five , user . If the user presses the fault reset button 64 , the the controller 75 determines if it is controlling a two -wire controller 75 will proceed from step 458 to step 462 and motor ( step 404 ) . If yes , the controller 75 pulses the motor clear the fault message displayed , then stop the drive 10 about three times ( step 406 ) , then proceeds back to step 376 . ( step 448 ). If the timer exceeds the time value , the controller If the motor is not a two -wire ( e . g . , if the motor is a 75 will proceed from step 460 to step 464 and clear the fault three -wire motor ), the controller 75 executes a series of three message displayed , then restart the drive 10 in PID mode forward -reverse cycles ( step 408 ) , then proceeds back to ( step 466 ) . step 376 . [0120 ] FIG . 36 illustrates a jam fault operation of the [ 0117] FIG . 33 illustrates a line or pipe break fault opera controller 75 . When a jam has been detected ( step 468 ) , the tion of the controller 75 . During PID control (step 410 ) , the fault log is updated ( step 470 ). After step 470 , the motor is controller 75 determines if a pipe break parameter ( e . g ., pipe coasted to a stop and a “ Foreign Object Jam ” fault message break detection parameter 314 from FIG . 25 ) is enabled is displayed ( step 472 ), then the drive 10 is stopped ( step ( step 412 ). The controller 75 continues back to step 410 until 474 ). the parameter is enabled . If the controller 75 determines that [0121 ] FIG . 37 illustrates an overtemperature fault opera the parameter is enabled at step 412 , a timer is incremented tion of the controller 75 . When the drive 10 is powered ( step ( step 414 ) , and the controller 75 determines if the pump is 476 ) , the controller 75 determines if the power module in sleep mode ( step 416 ). If the pump is in sleep mode, the temperature is too high ( step 478 ) , for example , using the timer is reset ( step 418 ) and the controller 75 reverts back to overheat prevention operation in FIG . 30 . If the power step 410 . If the pump is not in sleep mode , the controller 75 , module temperature is not too high , the fault is cleared ( step at step 420 , determines if the timer has been incremented 480 ) and the controller 75 reverts back to step 476 . If the above a certain number of days ( e . g . , as set by the number power module temperature is too high , the fault log is of days without sleep parameter 316 ). If the timer has not updated ( step 482 ) , the motor is coasted to a stop and a exceeded the set number of days , then the controller 75 “ Drive Temp - Auto Restart Pending” fault message is dis proceeds back to step 410 . If the timer has exceeded the set played ( step 484 ) , and a fault timer is incremented ( step number of days , the motor is coasted to a stop and a 486 ) . The controller 75 then continuously determines if the “ possible pipe break ” fault message is displayed ( step 422 ) , user has pressed the fault reset button 64 ( step 488 ) until the causing the drive 10 to be stopped ( step 424 ) . timer has been incremented past a value ( step 490 ) . If the [ 0118 ]. FIG . 34 illustrates a dry run detection operation of user has pressed the fault reset button 64 or if the timer has the controller 75 . During PID control ( step 426 ), the con incremented past the value , the controller 75 proceeds from troller 75 determines, at step 428 , if the frequency output to step 488 or step 490 , respectively , to step 492 to check if the the motor is greater than a frequency preset value ( e . g . , fault condition is still present. If the fault condition is still about 30 Hz) . If so , a timer is reset ( step 430 ) and the present, the controller 75 reverts back to step 486 . If the fault controller 75 reverts back to step 426 . If the frequency is condition is not present, the controller 75 clears the fault under the frequency preset value , the controller 75 then ( step 480 ) and reverts back to step 476 . determines , at step 432 , if the pressure is greater than a [0122 ] The motor 11 and pump 12 combination can satisfy pressure preset value ( e . g ., about 10 PSI) . If so , the timer is typical performance requirements as specified by the pump reset ( step 430 ) and the controller 75 reverts back to step manufacturer while maintaining current under service factor 426 . If the pressure is under 10 PSI, the timer is incremented amps as specified for the motor 11 . Performance can match ( step 434 ) and the controller 75 determines if the timer has that of a typical capacitor start / capacitor run control box for reached 15 seconds ( step 436 ) . If not , the controller 75 each motor HP offering . If the motor 11 performs outside of reverts back to step 426 . However , if the timer has reached such specifications , the controller 75 can generate a fault and 15 seconds, the controller 75 determines that a dry run has stop the motor 11 . For example , FIG . 38 illustrates an occurred and executes a dry run fault operation ( step 438 ) . overcurrent fault operation of the controller 75 . When the The preset value in step 428 can be checked to ensure the drive 10 is powered (step 494 ) , the controller 75 determines motor 11 is operating at a normal operating frequency ( e . g . , if there is a high current spike ( step 496 ) , for example , using above 30 Hz ) . the overcurrent prevention operation of FIG . 31 . If there is [0119 ] FIG . 35 illustrates a dry run fault operation of the no high current spike , the fault is cleared (step 498 ) and the controller 75 . The controller 75 can proceed to step 440 if controller 75 reverts back to step 494 . If there a high current step 438 of FIG . 34 was reached . From step 440 , the spike , the fault log is updated (step 500 ) , the motor is controller 75 can check if a reset counter value is less than coasted to a stop and a “Motor High Amps - Auto Restart a set value ( e . g . , the value set under the number of resets Pending ” fault message is displayed ( step 502 ) , and a fault parameter 320 of FIG . 26 ) at step 442 . If the reset counter timer is incremented ( step 504 ) . The controller 75 then is not less than the set value , the controller 75 can update a continuously determines if the user has pressed the fault fault log (step 444 ) , coast the motor to a stop and display a reset button 64 ( step 506 ) until the timer has been incre “ Dry Run ” fault message ( step 446 ) , so that the drive 10 is mented past a value ( step 508 ) . If the user has pressed the stopped (step 448 ) . If, at step 442 , the reset counter is less fault reset button 64 or if the timer has incremented past the than the set value , the reset counter is incremented ( step 450 ) value , the controller 75 proceeds from step 506 or step 508 , and the fault log is updated ( step 452 ) . The controller 75 can respectively , to step 510 to check if the fault condition is still then coast themotor to a stop and display a “ Dry Run - Auto present. If the fault condition is still present, the controller US 2017 /0234117 A1 Aug . 17 , 2017
75 reverts back to step 504 . If the fault condition is not respectively , to step 572 to check if the fault condition is still present, the controller 75 clears the fault ( step 498 ) and present. If the fault condition is still present, the controller reverts back to step 494 . 75 reverts back to step 566 . If the fault condition is not [0123 ] FIG . 39 illustrates an overvoltage fault operation of present, the controller 75 reverts back to step 558 . the controller 75 . When the drive 10 is powered (step 512 ) , [0127 ] FIG . 43 illustrates a shorted transducer fault opera the controller 75 determines if a maximum bus voltage has tion of the controller 75. While in PID mode ( step 574 ) , the been exceeded (step 514 ) . If the bus voltage has not controller 75 determines if a current measured at the trans exceeded the maximum value , the fault is cleared (step 516 ) ducer input is greater than a value , such as 25 milliamps and the controller 75 reverts back to step 512 . If the bus ( step 576 ) . If the current is not greater than the value , the voltage has exceeded the maximum value , the fault log is controller 75 reverts back to step 574 . If the current is greater updated ( step 518 ), the motor is coasted to a stop and an than the value, the fault log is updated (step 578 ) , the motor “ Over Voltage Auto Restart Pending " fault message is is coasted to a stop and a “ Shorted Transducer - Auto displayed (step 520 ), and a fault timer is incremented ( step Restart Pending ” fault message is displayed ( step 580 ) , and 522 ) . The controller 75 then continuously determines if the a fault timer is incremented (step 582 ) . The controller 75 user has pressed the fault reset button 64 ( step 524 ) until the then continuously determines if the user has pressed the fault timer has been incremented past a value ( step 526 ) . If the reset button 64 (step 586 ) until the timer has been incre user has pressed the fault reset button 64 or if the timer has mented past a value (step 588 ) . If the user has pressed the incremented past the value , the controller 75 proceeds from fault reset button 64 or if the timer has incremented past the step 524 or step 526 , respectively, to step 528 to check if the value , the controller 75 proceeds from step 586 or step 588 , fault condition is still present. If the fault condition is still respectively , to step 590 to check if the fault condition is still present , the controller 75 reverts back to step 522. If the fault present. If the fault condition is still present, the controller condition is not present, the controller 75 clears the fault 75 reverts back to step 582 . If the fault condition is not ( step 516 ) and reverts back to step 512 . present, the controller 75 reverts back to step 574 . [0124 ] FIG . 40 illustrates an internal fault operation of the [0128 ] FIGS. 44A -44B illustrate a multiple faults opera controller 75 . When the drive 10 is powered ( step 530 ), the tion of the controller 75 . Referring to FIG . 44A , when the controller 75 determines if any internal voltages are out of drive 10 is powered ( step 592 ), the controller 75 continu range ( step 532 ) . If the internal voltages are not out of range , ously determines if a fault has occurred ( step 594 ) . If a fault the fault is cleared ( step 534 ) and the controller 75 reverts has a occurred , a counter is incremented (step 596 ) and the back to step 530 . If the internal voltages are out of range , the controller 75 determines if the counter has reached a value , fault log is updated (step 536 ) , the motor is coasted to a stop such as ten ( step 598 ) . If the counter has reached the value , and an " Internal Fault - Auto Restart Pending” fault mes the motor is coasted to a stop and a “ Multiple Faults ” fault sage is displayed ( step 538 ) , and a fault timer is incremented message is displayed ( step 600 ), and the drive 10 is stopped ( step 540 ) . The controller 75 then continuously determines ( step 602 ) . The steps of FIG . 44B serve to provide a time if the user has pressed the fault reset button 64 (step 542 ) frame for which the counter can reach the value . When the until the timer has been incremented past a value ( step 544 ) . drive 10 is powered ( step 592 ) , the controller 75 continu If the user has pressed the fault reset button 64 or if the timer ously determines if the counter ( i. e ., the counter in step 596 has incremented past the value , the controller 75 proceeds of FIG . 44A ) has been incremented ( step 604 ) . If so , a timer from step 542 or step 544 , respectively, to step 546 to check is incremented ( step 606 ) . The controller 75 continues to if the fault condition is still present. If the fault condition is increment the timer as long as the counter is above zero until still present, the controller 75 reverts back to step 540 . If the the timer reaches a value, such as thirty minutes ( step 608 ) . fault condition is not present, the controller 75 clears the Once the timer has reached the value , the counter is decre fault ( step 534 ) and reverts back to step 530 . mented and the timer is reset ( step 610) . [ 0125 ] FIG . 41 illustrates a ground fault operation of the [0129 ] FIG . 45 illustrates an undervoltage fault operation controller 75 . When the drive 10 is powered ( step 548 ) , the of the controller 75 . When the drive 10 is powered ( step controller 75 continuously determines if there is current flow 612 ) , the controller 75 determines if the bus voltage is below between an earth , or ground , lead and any motor lead (step a minimum value ( step 614 ) . If the bus voltage is not below 550 ) . If so , the fault log is updated (step 552 ) , the motor is the minimum value , the fault is cleared ( step 616 ) and the coasted to a stop and a “ Ground Fault ” fault message is controller 75 reverts back to step 612 . If the bus voltage is displayed ( step 554 ), and the drive 10 is stopped ( step 556 ) . below the minimum value , the fault log is updated ( step [0126 ] FIG . 42 illustrates an open transducer fault opera 618 ), the motor is coasted to a stop and an “Under Voltage tion of the controller 75 . While in PID mode (step 558 ), the Auto Restart Pending " fault message is displayed ( step 620 ), controller 75 determines if a currentmeasured at the trans the fault log is saved in memory, such as the device ' s ducer input is less than a value , such as 2 milliamps ( step electrically erasable programmable read - only memory , or 560 ) . If the current is not less than the value , the controller EEPROM ( step 622 ) and a fault timer is incremented (step 75 reverts back to step 558 . If the current is less than the 624 ) . The controller 75 then continuously determines if the value , the fault log is updated (step 562 ) , the motor is user has pressed the fault reset button 64 ( step 626 ) until the coasted to a stop and an “ Open Transducer - Auto Restart timer has been incremented past a value ( step 628 ) . If the Pending” fault message is displayed ( step 564 ) , and a fault user has pressed the fault reset button 64 or if the timer has timer is incremented ( step 566 ) . The controller 75 then incremented past the value, the controller 75 proceeds from continuously determines if the user has pressed the fault step 626 or step 628 , respectively , to step 630 to check if the reset button 64 ( step 568 ) until the timer has been incre fault condition is still present. If the fault condition is still mented past a value ( step 570 ). If the user has pressed the present, the controller 75 reverts back to step 624 . If the fault fault reset button 64 or if the timer has incremented past the condition is not present, the controller 75 clears the fault value , the controller 75 proceeds from step 568 or step 570 , ( step 616 ) and reverts back to step 612 . US 2017 /0234117 A1 Aug . 17 , 2017 10
[0130 ] FIG . 46 illustrates a hardware fault operation of the 700 ) . If the control pad 14 is not locked , the controller 75 controller 75 . When the controller 75 recognizes a hardware sets the LED indicators 66 on or off accordingly ( step 702 ) error ( step 632 ), the fault log is updated ( step 634 ) . After and the main menu , as described with respect to FIG . 16 , is step 634 , the motor is coasted to a stop and a " Hardware displayed ( step 704 ) . Error” fault message is displayed (step 636 ) , then the drive [0135 ] FIG . 51 illustrates a fault log button control opera 10 is stopped (step 638 ) . tion , according to some embodiments . When the fault log [0131 ] FIG . 47 illustrates an external fault operation of the button 46 is pressed ( step 706 ) , the controller 75 sets the controller 75 . When the drive 10 is powered ( step 640 ), the LED indicators 66 on or off accordingly ( step 708 ) and the controller 75 continuously determines if an external fault fault log is displayed , detailing fault history information to parameter is present, for example , from a relay input at the the user ( step 710 ) . input power terminal block 28 or the digital input/ output [0136 ] FIG . 52 illustrates an enter button control opera ( 1/ 0 ) spring terminals 30 ( step 642 ) . If so , the controller 75 tion , according to some embodiments . When the enter determines if a digital input is high ( step 644 ) . If the digital button 56 is pressed (step 712 ) , the controller 75 first input is not high , the controller 75 determines if the external determines if the fault log is active ( e . g ., being displayed ) at fault is active ( step 646 ) . If the external fault is not active , step 714 or if the stopped status screen is being displayed the controller 75 reverts back to step 640 . If the external fault (step 716 ) . If either step 714 or step 716 is true , the controller is active , the controller 75 clears an " external fault” fault 75 executes an invalid key error operation ( step 718 ). If message ( if it is being displayed ) at step 648 and the device ' s neither the fault log or stopped status screen are being previous state and operation are restored ( step 650) . If , at displayed , the controller 75 determines if the control pad 14 step 644 , the digital input is high , the fault log is updated is locked ( step 720 ) . If so , the controller 75 executes a keys ( step 652) and the device ' s current state and operation are locked error operation ( step 722 ) . If the control pad 14 is not saved (step 654 ). Following step 654 , the motor is coasted locked , the controller 75 determines if the display currently to a stop and a “ External Fault ” fault message is displayed selecting a menu option or a parameter ( step 724 ) . If the ( step 656 ), then the drive 10 is stopped ( step 658 ). display is currently selecting a menu option , the controller [0132 ] FIGS . 48 -63 are flow charts describing control 75 will enter the selected menu ( step 726 ) . If the display is operations for the control pad 14 according to some embodi currently selecting a parameter option , the controller 75 ments of the invention . FIG . 48 illustrates a pump -out button determines if the parameter is highlighted ( step 728 ) . If the control operation , according to some embodiments . When parameter is highlighted , the controller 75 saves the value of the pump -out button 40 is pressed ( step 660 ) , the controller the selected parameter and cancels the highlighting of the 75 first determines if the control pad 14 is locked , or in the parameter ( step 730 ) . If , at step 728 , the parameter is not password protection mode ( step 662 ) . If so , the controller 75 highlighted , the controller 75 determines if the parameter executes a keys locked error operation ( step 664 ) . If not, a can be changed with the motor is running and the drive 10 valve screen 666 is displayed ( step 668) asking the user if a is stopped ( step 732 ). If not, a running error operation is valve is open . Once the user chooses if the valve is open or executed (step 734 ) . If the parameter may be changed , then not and presses enter, a valve parameter value is changed the selected parameter is highlighted ( step 736 ) . ( step 670 ) . The controller 75 then determines , at step 672 , if 0137 ) FIG . 53 illustrates a back button control operation , the valve parameter value is yes (i . e ., if the valve is open ). according to some embodiments . When the back button 54 If the valve parameter is not yes ( i. e ., if the user selected that is pressed ( step 738 ) , the controller 75 determines if a status the valve was not open ), a stopped screen is displayed ( step screen is being displayed ( step 740 ) . If so , an invalid key 674 ) , indicating that the pump 12 is stopped . If the valve error operation is executed (step 742 ) . If a status screen is parameter is yes , the controller 75 sets LED indicators 66 on not being displayed , the controller 75 determines if a line in or off accordingly ( step 676 ), displays a status screen 678 the display is highlighted ( step 744 ) . If so , the new value on ( step 680 ) , and runs the pump out operation to drive the the highlighted line is cancelled and the highlighting is motor 11 in the pump out mode ( step 682 ). The status screen cancelled as well ( step 746 ) . If , at step 744 , there is no 678 can include information about the pump 12 , such as highlighted line , the parent, or previous, menu is displayed motor frequency , pressure , and motor current during the (step 748 ). pump out mode. [0138 ] FIG . 54 illustrates an up /down button control [ 0133 ] FIG . 49 illustrates a pressure preset button control operation , according to some embodiments . When either the operation , according to some embodiments . When the pres up or down directional button 52 is pressed ( step 750 ) , the sure preset button 42 is pressed ( step 684 ), the controller 75 controller 75 determines if a line in the display is highlighted first determines if the control pad 14 is locked ( step 686 ) . If ( step 752 ) . If so , the controller 75 then determines if the auto so , the controller 75 executes a keys locked error operation line fill operation is being executed (step 754 ) . If so , the ( step 688 ). If the control pad 14 is not locked , the controller controller 75 proceeds to the manual line fill operation (step 75 sets the LED indicators 66 on or off accordingly ( step 756 ) , as described with reference to FIG . 9 , then scrolls to 690 ) and a preset pressure parameter is displayed ( step 692 ) . another value in the display ( step 758 ) . If the controller 75 The user can adjust the displayed pressure parameter using determines that the auto line fill operation is not being the keypad and hit enter to change the value of the preset executed at step 754 , the controller 75 proceeds to step 758 pressure parameter , changing the pressure set point for the and scrolls to another value in the display . If, at step 752 , the controller 75 (step 694 ). controller 75 determines that no line is highlighted , the [0134 ] FIG . 50 illustrates a main menu button control controller 75 then determines if a menu in the display can be operation , according to some embodiments . When the main scrolled (step 760 ) . If so , the menu is scrolled ( step 762 ) . If menu button 44 is pressed ( step 696 ), the controller 75 first not , an invalid key error operation is executed ( step 764 ) . determines if the control pad 14 is locked ( step 698 ) . If so , (0139 ] FIG . 55 illustrates a left/ right button control opera the controller 75 executes a keys locked error operation ( step t ion , according to some embodiments . When either the left US 2017 /0234117 A1 Aug . 17 , 2017 11 or right directional button 52 is pressed ( step 766 ), the 850 ) . If there is an active fault , the controller 75 determines controller 75 determines if a line in the display is highlighted if the fault condition is still present (step 852 ). If so , the ( step 768 ) . If not, an invalid key error operation is executed controller 75 stops the drive 10 ( step 854 ) , as described with ( step 770 ) . If, at step 768 , the controller 75 determines that reference to FIG . 10 . If not , the controller 75 first clears the the line is highlighted , the controller 75 then determines if fault (step 856 ), then stops the drive 10 ( step 854 ). a cursor in the display can be moved (step 772 ) . If so , the [0146 ] FIGS . 62A -62D illustrate LED indicator control cursor is moved ( step 774 ). If not, an invalid key error operations , according to some embodiments. As shown in operation is executed ( step 776 ) . FIG . 62A , if a fault is active and a restart is pending ( step [ 0140 ] FIG . 56 illustrates a password button control opera 856 ) , the Fault LED 72 blinks (step 858 ), and a “ Restart tion , according to some embodiments . When the password Pending ” message is displayed (step 860 ) . As shown in FIG . button 48 is pressed ( step 778 ) , the controller 75 first 62B , if a fault is active and the drive 10 is stopped ( step 862 ) , determines if the control pad 14 is locked ( step 780 ). If not, the Fault LED 72 blinks ( step 864 ), and a “ Drive Stopped ” a status screen is displayed (step 782 ) . If the control pad 14 message is displayed ( step 866 ) . As shown in FIG . 62C , if is locked , the controller 75 sets the LED indicators 66 on or a TPM is active and the drive 10 is still running ( step 868 ) , off accordingly ( step 784 ) and executes a keys locked error the Warning LED 70 is lit ( step 870 ) , and a message is operation ( step 786 ) . If a user then enters a password ( step displayed describing the warning ( step 872 ) . As shown in 788 ) , the controller 75 determines if the password is correct FIG . 62D , when the drive 10 is powered up ( step 874 ) , the ( step 790 ) . If the password is correct, any lockable keys are ON LED 68 is lit ( step 876 ). unlocked ( step 792 ) and the status screen is displayed ( step [0147 ] FIGS. 63A - 63D illustrate error display control 794 ) . If the password is incorrect , an invalid password error operations, according to some embodiments . As shown in operation is executed ( step 796 ) , then the status screen is FIG . 63A , for the invalid key error operation ( step 878 ) , a displayed ( step 794 ) . In some embodiments , the lockable “ Key Error! Invalid Key !” error screen can be displayed keys can include the directional buttons 52 , the language ( step 880 ) . The controller 75 can display the error screen for button 50 , the pump -out button 40 , the pressure preset a timeperiod , such as 0 . 9 seconds ( step 882 ) , then return the button 42 , and /or the main menu button 44 . display to the previous screen ( step 884 ). As shown in FIG . [0141 ] FIG . 57 illustrates a language button control opera 63B , for the keys locked error operation ( step 886 ) , an tion , according to some embodiments . When the language “ Error! Press Password Key” error screen can be displayed button 50 is pressed (step 796 ) , the controller 75 first ( step 888 ). The controller 75 can display the error screen for determines if the control pad 14 is locked ( step 798 ) . If so , a time period , such as 0 . 9 seconds ( step 890 ), then return the the controller 75 executes a keys locked error operation ( step display to the previous screen ( step 892 ). As shown in FIG . 800) . If the control pad 14 is not locked , the controller 75 63C , for the invalid password error operation (step 894 ) , an sets the LED indicators 66 on or off accordingly (step 802 ) “ Error ! Invalid Password !” error screen can be displayed and a language parameter is displayed ( step 804 ) . The user ( step 896 ) . The controller 75 can display the error screen for can change the displayed language using the keypad and hit a time period , such as 0 . 9 seconds ( step 898 ) , then return the enter to update the language parameter ( step 806 ) . display to the previous screen ( step 900 ) . As shown in FIG . [0142 ] FIG . 58 illustrates a status button control operation , 63D , for the running error operation (step 902 ), an “ Error ! according to some embodiments . When the status button 58 Stop before editing” error screen can be displayed ( step is pressed ( step 808 ), the controller 75 sets the LED indi 904 ) . The controller 75 can display the error screen for a cators 66 on or off accordingly (step 810 ) and determines if time period , such as 0 . 9 seconds ( step 906 ) , then return the a current status screen is being displayed ( step 812 ). If not, display to the previous screen ( step 908 ) . the current status screen 814 or 816 is displayed (step 818 ) . [0148 ] It will be appreciated by those skilled in the art that If the controller 75 , at step 812 , determines that the current while the invention has been described above in connection status screen is being displayed , the currents status screen is with particular embodiments and examples, the invention is cleared and a power status screen 820 or 822 is displayed not necessarily so limited , and that numerous other embodi ( step 824 ). ments , examples , uses, modifications and departures from 10143] FIG . 59 illustrates a stop button control operation , the embodiments , examples and uses are intended to be according to some embodiments . When the stop button 60 is encompassed by the claims attached hereto . The entire pressed (step 826 ) , the controller 75 sets the LED indicators disclosure of each patent and publication cited herein is 66 on or off accordingly ( step 828 ) and a stopped status incorporated by reference , as if each such patent or publi screen 830 is displayed (step 832 ) . The controller 75 then cation were individually incorporated by reference herein . stops the drive 10 (step 834 ), as described with reference to Various features and advantages of the invention are set FIG . 10 . forth in the following claims. [0144 ] FIG . 60 illustrates an automatic start button control 1 . A controller for a pump driven by a motor, the pump in operation , according to some embodiments. When the auto fluid communication with a fluid system , the controller matic start button 62 is pressed ( step 836 ), the controller 75 comprising : sets the LED indicators 66 on or off accordingly (step 838 ) a variable frequency drive circuit that controls operation and a status screen 840 is displayed ( step 842 ). The con of the pump ; and troller 75 then runs the automatic line fill operation ( step a control panel connected to the variable frequency drive 844 ) , as described with reference to FIG . 8 . circuit , 10145 ] FIG . 61 illustrates a fault reset button control the control panel including an automatic start button operation , according to some embodiments . When the fault and a stop button , reset button 64 is pressed (step 846 ) , the controller 75 the variable frequency drive circuit automatically oper determines if there is an active fault ( step 848 ) . If not, the ating in a line fill mode when the pump starts when controller 75 executes an invalid key error operation ( step the automatic start button is engaged , US 2017 /0234117 A1 Aug . 17 , 2017 12
the variable frequency drive circuit disabling the pump 13 . The method of claim 6 , wherein causing the pump to when the stop button is engaged . enter the sleep mode includes setting the operating fre 2 . The controller of claim 1 wherein the variable fre quency of the motor to zero Hertz . quency drive circuit operates in the line fill mode by 14 . A controller for a pump driven by a motor, the pump determining a pressure in the fluid system when the pump in fluid communication with a fluid system , the controller starts . comprising : 3 . The controller of claim 2 , wherein the variable fre a control panel including a display, directional buttons , quency drive circuit operates the motor at a low frequency and an enter button ; and for a time period when the pressure in the fluid system is less a variable frequency drive circuit that controls operation than a minimum pressure set point in order to fill the fluid of the pump, the variable frequency drive circuit con system . nected to the control panel, the variable frequency drive 4 . The controller of claim 3 , wherein the variable fre circuit configured to : quency drive circuit operates the motor at a normal fre monitor a pressure in the fluid system , quency after the timer period has expired in order to main monitor and adjust an operating frequency of the motor tain a normal pressure set point. to maintain the pressure at a pressure set point, the 5 . The controller of claim 1 , wherein the variable fre pressure set point being programmable by a user quency drive circuit automatically starts and operates in the using the directional buttons and the enter button , line fill mode after a power interruption when the automatic based on the monitored operating frequency , cause the start button is engaged . pump to temporarily boost the pressure in the fluid 6 . A method of controlling a pump driven by a motor, the system to a temporary boost set point for a first time pump in fluid communication with a fluid system , the period , the temporary boost set point being program method comprising : mable by a user using the directional buttons and the monitoring a pressure in the fluid system ; enter button , monitoring and adjusting an operating frequency of the determine whether the temporarily boosted pressure in motor to maintain the pressure at a pressure set point; the fluid system stays above the pressure set point for based on the monitored operating frequency, causing the a second time period , and pump to temporarily boost the pressure in the fluid cause the pump to enter a sleep mode when the tem system to a temporary boost set point for a first time porarily boosted pressure stays above the pressure period , the temporary boost set point being greater than set point through the second time period . the pressure set point; 15 . The controller of claim 14 , wherein the variable determining whether the temporarily boosted pressure in frequency drive circuit is configured to cause the pump to the fluid system stays above the pressure set point for resume normal operation when the temporarily boosted a second time period ; and pressure drops below the pressure set point within the causing the pump to enter a sleep mode when the tem second time period . porarily boosted pressure stays above the pressure set 16 . The controller of claim 14 , wherein the variable point through the second time period . frequency drive circuit is configured to monitor the pressure 7 . The method of claim 6 and further comprising causing in the fluid system while the pump is in the sleep mode and the pump to resume normal operation when the temporarily determine whether the pressure in the fluid system reaches boosted pressure drops below the pressure set point within a wakeup pressure , the wakeup pressure being less than the the second time period . pressure set point, the wakeup pressure being programmable 8 . The method of claim 6 and further comprising moni by a user using the directional buttons and the enter button . toring the pressure in the fluid system while the pump is in 17 . The controller of claim 16 , wherein the variable the sleep mode and determining whether the pressure in the frequency drive circuit is configured to cause the pump to fluid system reaches a wakeup pressure , the wakeup pressure leave the sleep mode when the pressure drops below the being less than the pressure set point. wakeup pressure . 9 . The method of claim 8 and further comprising causing 18 . The controller of claim 14 , wherein the variable the pump to leave the sleep mode when the pressure drops frequency drive circuit is configured to cause the pump to below the wakeup pressure . enter the sleep mode by setting the operating frequency of 10 . The method of claim 6 , wherein the temporary boost the motor to zero Hertz . set point is three pounds per square inch above the pressure 19 . The controller of claim 14 , wherein the control panel set point. includes a stop button , the variable frequency drive circuit 11 . The method of claim 6 , wherein the temporary boost disabling the pump when the stop button is engaged . set point is modifiable by a user. 20 . The controller of claim 14 , wherein the display is a 12 . The method of claim 6 , wherein causing the pump to liquid crystal display. enter the sleep mode includes stopping the motor. * * * * *