GB2486071A

GB2486071A - Shower pump system with diagnostic capabilities

Info

Publication number: GB2486071A
Application number: GB201120686A
Authority: GB
Inventors: Omar Beggs; David Mcmullan
Original assignee: Munster Simms Engineering Ltd
Current assignee: Munster Simms Engineering Ltd
Priority date: 2010-12-02
Filing date: 2011-12-01
Publication date: 2012-06-06
Anticipated expiration: 2031-12-01
Also published as: GB201120686D0; GB201020421D0; GB2486071B

Abstract

The invention relates to a water delivery system 10 comprising a water delivery apparatus, such as a shower head 12, and which includes a pump 18 located in a shower tray drain, an electric motor for the pump, a flow monitor 26, and a control system 22 which activates a visual indicator (56 figure 2) depending on a flow signal received from the flow monitor. The indicator allows a user, such as an installation or maintenance engineer, to determine if the communication link between the water delivery apparatus and the control system is correctly established. A second mode of activation allows the user to determine if the communication link between the water delivery apparatus and the control system is correctly established during installation and before the system is fully operational. A later embodiment relates to a control system for the water delivery system.

Description

Shower Pump System with Diagnostic Capabilities The present invention relates to water delivery systems, especially showers. The invention relates particularly to water delivery apparatus associated with a pumped drainage system.

A first aspect of the present invention provides a water delivery system comprising a water delivery apparatus arranged to deliver water into a receptacle; a drainage system connected to said receptacle, said drainage system including a pump; a motor for operating said pump; a power supply for said motor; a control system comprising means for controlling the operation of said motor by said power supply; a flow monitor for measuring the flow of water through said water delivery apparatus during use, said flow monitor generating a signal at least when water is flowing through said delivery apparatus, said signal being indicative of the measured flow of water, said flow signal, or a derivative thereof, being communicated to said control system via a communication link, wherein said control system is arranged to activate an indicating device in a first mode in response to receiving said flow signal via said communication link, and wherein, advantageously, said flow monitor is configured to generate said signal when no water is flowing through said delivery apparatus, said signal indicating that no water is flowing through said delivery apparatus, said control system being arranged to activate said indicating device in a second mode, different from said first mode, in response to receiving said signal indicating that no water is flowing through said delivery apparatus.

Typically, the indicating device is not activated when no signal is received via the communication link, and such non-activation may be regarded as a third mode of operation. Alternatively, the control system may activate the indicating device in a third mode, different from said first and second modes, in response to determining that no signal is received via said communications link.

The indicating device allows a user, and especially an installation or maintenance engineer, to determine if the communication link between the water delivery apparatus and the control system is correctly established.

The second mode of activation supported by the preferred system allows the user to determine if the communication link between the water delivery apparatus and the control system is correctly established during installation and before the system is fully operational.

The communications link typically comprises a wired electrical connection, but may alternatively comprise a wireless link.

The indicating device preferably comprises at least one visual indicator, e.g. at least one lamp (typically at least one LED), or a visual display device. In the preferred embodiment, the indicating device comprises a single lamp, e.g. LED, which, in said first mode, is caused to flash at a first frequency. Where said second mode is supported, said lamp is caused to flash at a second frequency different from said first frequency (typically lower than said first frequency). In said third mode, said LED may be turned off.

In the preferred embodiment, when water is flowing through said delivery apparatus, the flow signal has a frequency that is indicative of the measured rate of flow of water through said delivery apparatus.

Advantageously, when no water is flowing through said delivery apparatus, said flow signal has a frequency that is indicative of no water flowing through said water delivery apparatus, typically a frequency that is lower than any frequency that could be generated in response to a measured rate of flow of water through said delivery apparatus. In such embodiments, the indicator device may be operated to flash relatively slowly when the flow signal indicates that no water is flowing, and relatively quickly when the flow signal indicates that water is flowing.

The indicating device is preferably located at said control system or said power supply, e.g. as part of a housing for said control system or a housing for said power supply. In preferred embodiments, said power supply and said control system are co-located, preferably in a common housing, and said indicating device is advantageously provided as part of said common housing.

The motor is preferably a variable speed motor, typically an electric motor, e.g. a DC motor. The power supply is typically an electrical power supply and usually includes a transformer. The power supply may also include a rectifier for converting AC to DC.

Advantageously, the control system is arranged to control the speed of the motor, and therefore the speed of the pump, in response to the measured rate of flow indicated by said flow signal. Preferably, the speed of the motor is controlled in proportion to the rate of flow, e.g. motor speed increases as flow rate increases and decreases as flow rate decreases.

The control system may be arranged to control the supply of power to said motor from said power supply in order to control the speed of the motor.

Typically, the speed of the motor is proportional to the voltage supplied to the motor and so the control system controls the voltage supplied to the motor. This may be achieved by means of a pulse width modulating system.

The control system may be configured to process flow signals of different types, e.g. flow signals in which the frequency of the flow signal is indicative of the measured rate of flow, and flow signals in which the amplitude of the signal is indicative of the measured rate of flow. To this end the control system preferably includes respective processing circuitry for each type of flow signal, and may also include a switch that is operable to direct received flow signals to suitable processing circuitry. The control system may include a user operable input device for setting the state of said switch. The control system may include an interrupt I/O unit for processing frequency-type flow signals. The control system may include an ND converter for processing voltage-type flow signals.

A second aspect of the invention provides said control system for use in said water delivery system, said control system being arranged to activate said indicating device in a first mode in response to receiving said flow signal via said communication link, and wherein, advantageously, said flow monitor is configured to generate said signal when no water is flowing through said delivery apparatus, said signal indicating that no water is flowing through said delivery apparatus, said control system being arranged to activate said indicating device in a second mode, different from said first mode, in response to receiving said signal indicating that no water is flowing through said delivery apparatus.

Embodiments of the invention are particularly suitable for use with shower systems. For example, said water delivery apparatus may comprise a shower and said receptacle may comprise a shower tray. However, embodiments of the invention may be used with any water dispensing system. The water dispensing system may be installed in a building, e.g. a domestic or commercial building, or in a vehicle, e.g. a caravan, recreational vehicle or boat.

Further advantageous aspects of the invention will become apparent to those ordinarily skilled in the art upon review of the following description of a specific embodiment of the invention and with reference to the accompanying drawings in which: Figure 1 is a schematic representation of a shower system with a pumped drainage facility; and Figure 2 is a schematic diagram of a pump control system for use with the shower system of Figure 1.

Referring now to Figure 1 of the drawings there is shown, generally indicated as 10, a water delivery system in the form of a shower system.

The system 10 has a water delivery apparatus which, in the illustrated embodiment, is assumed to be a shower and as such includes a spray head 12. The shower may include other conventional components, e.g. control apparatus, user controls, electrical heater and/or pump, depending on type. As is described in more detail hereinafter, a flow monitor is also provided for measuring the flow, typically the rate of flow, of water through the apparatus during use.

The spray head 12 is arranged to deliver water into a receptacle, in this case a shower tray 14. In use, water is drained from the tray 14 via a drainage system that includes a drainage pipe 16. A pump 18 is connected to the drainage pipe 16 in order to pump water from the tray 14 to any suitable waste water location, e.g. a drain or a tank (not shown).

The pump 18 is driven by a motor 20, typically an electrically powered motor (usually a DC motor), preferably a motor with variable speed control.

Motors and pumps such as those provided by Munster Simms Engineering Limited of Bangor, County Down, United Kingdom under the WHALE brand are suitable for use in the system 10. The motor 20 is controlled by a control unit 22. In use, the control unit 22 operates the motor 20, including supplying power to the motor in this example, in order to operate the pump 18 when required (and so may be referred to as a pump control unit).

The spray head 12 receives water from any suitable source, e.g. a water tank (not shown) or mains water supply, via a flow pipe 24. A flow monitor 26 is coupled to the flow pipe 24 in order to measure the flow of water in the pipe 24. The flow monitor 26 generates an output signal that is indicative of the flow of water in the pipe 24 (typically a measure of the rate of flow in the pipe 24). The flow monitor 26 is connected (directly or indirectly, wired or wireless connection) to the control unit 22 so that the control unit 22 receives the output signal of the flow monitor 26. In the illustrated embodiment, the flow monitor is connected directly to the control unit 22 for this purpose. Alternatively, the flow monitor 26 may be connected to, or may form part of, a shower control unit (not shown), the shower control unit being connected to the pump control unit 22 such that the control unit 22 receives the output signal of the flow monitor 26, or a derivative thereof. By way of example, some commercially available thermostatic showers have an integral water flow monitor and a control unit that provides an output signal that is indicative of the rate of flow of water to the spray head. In cases where a flow monitor is not an integral part of the shower, or other, apparatus, a separate flow monitor may be provided.

Advantageously, during use, the pump control unit 22 controls the operation of the pump motor 20 depending on the output signal of the flow monitor 24. In particular, the control unit 22 controls the speed of the pump motor 20 depending on the measured rate of flow of water to the spray head 12. For example, the control unit 22 may control the speed of the motor 20 in proportion to the rate of flow of water in the pipe 24. This allows the operation of the pump 18 to be controlled to match or substantially match the rate of water that is being delivered into the tray 14. An advantage of this is that it prevents the pump from running too slowly (in which case the tray could overflow), or too quickly (causing suction noise).

Referring now to Figure 2 of the drawings, there is shown an embodiment of the pump control unit 22. In the illustrated embodiment, the unit 22 is a combined power supply and control unit for the pump 18 and so includes components for supplying power to the pump motor 20 as well as components for controlling the operation, and in particular the speed, of the pump motor 20, preferably all in a common unit as indicated by numeral 22. In alternative embodiments, the components of unit 22 could be provided in two or more separate units as is convenient and with appropriate interconnection as would be apparent to a skilled person.

The power supply components of the unit 22 may include an electrical transformer 30 which, in use, is connected to an external electrical power supply, e.g. a mains supply (not shown). The transformer 30 transforms the voltage from the external supply to a level that is suitable for use with the pump motor 20. Assuming that the external power supply is an AC supply and that the motor 20 is a DC motor, then the unit 22 includes a rectifier 32, which may also include a heat sink. The rectified supply is provided to the motor 20, in this example via a motor driver 34 which, in turn, supplies power to the pump motor 20. Typically, a fuse 36 is provided between the rectifier 32 and the motor driver 34.

The control components of the unit 22 include a controller 40 which, typically, comprises a programmable microcontroller or other programmable processor or logic circuit. Conveniently, the controller 40 is powered from the transformer 30 via a voltage regulator 42.

The controller 40 controls the operation of the pump motor 20, via the motor driver 34 in the illustrated embodiment. Preferably, the controller 40 includes, or is co-operable with, a pulse width modulation (PWM) system for supplying the pump motor 20 with a pulse width modulated voltage supply in order to control the speed of the motor 32. The PWM system comprises the motor driver 34, which controls the effective voltage supplied to the motor 20, and a PWM generator 44 incorporated into, or otherwise associated with, the controller 40 for controlling the operation of the motor driver 34. The driver 34 modulates the electrical supply voltage such that the voltage supply signal to the motor 20 takes the form of a square wave. This controls the effective voltage that is supplied to the motor 20. For example, for a I 2V DC supply voltage modulation may be applied at a frequency of 8 kHz. With an exemplary PWM duty cycle of 66.6%, the effective applied voltage to the pump is 8 volts. By soft-starting the PWM generator the pump in rush current is limited thereby reducing electrical interference and prolonging pump motor life.

In alternative embodiments, the control unit 22 may include alternative means for allowing the controller 40 to control the speed of the motor 20.

The control unit 22 includes an input 46 for receiving an electrical signal from the shower (or other flow sensor/water delivery apparatus) that is indicative of the water flow, typically the rate of flow, being delivered by the apparatus. In the present example, the electrical signal comprises the signal output from the flow monitor 26, or a derivative thereof.

Accordingly, there is an electrical connection between the control unit 22 and the water delivery apparatus to allow the flow signal to be communicated. The connection may be made for example between the control unit 22 and the flow monitor 26, or between the control unit 22 and a control apparatus for the water delivery apparatus. In the present embodiment, it is assumed that the connection is a wired connection. In alternative embodiments, the connection may be wireless, in which case the control unit 22 and the flow monitor 26/control apparatus are provided with a suitable wireless receiver/f ransm itter.

The flow monitor 26 may be of any conventional type, e.g. a frequency type flow monitor that produces an output signal having a frequency that is dependent, e.g. proportional, to the measured rate of flow, or a voltage type flow monitor that produces an output signal having a voltage amplitude that is dependent, e.g. proportional, to the measured rate of flow.

In order to accommodate flow monitors of different types, the control unit 22 advantageously includes respective processing components for each type. For frequency type flow monitors, the control unit 22 preferably includes an interrupt I/O unit 48. The flow rate signal at input 46 is provided to the interrupt I/O unit 48 and controller 40 is programmed to determine the frequency of the received signal using program interrupts caused by the incoming signal. For voltage-type flow monitors, the control unit 22 preferably includes an A/D converter 50. The flow rate signal at input 46 is provided to the A/D converter 50, which converts the signal into a digital signal that is usable by the controller 40. Conveniently, the control unit 22 includes a switch 52 for selectably connecting the input 46 to the interrupt I/O unit 48 or the A/D converter 50. The control unit 22 preferably includes a user control 54, e.g. in the form of an electrical jumper connector, for selecting the setting of the switch 52.

In the present embodiment, it is assumed that the received flow rate signal is analogue. It will be apparent that in alternative embodiments, the received flow rate signal may be digital, in which case the controller 40 may process the signal by other means.

The control unit 22 includes an output device 56 in the preferred form of a lamp, e.g. an LED, or other indicator (typically an audio and/or visual indicator). In use, the indicator 56 provides the user with an indication of the status of the system 10. In particular, the control unit 22 is arranged to activate the indicator 56 when a signal is received at input 46. Hence, when a flow rate signal is received from the shower apparatus, or other water delivery apparatus, the indicator 56 is activated. This allows the user to determine not only that water is flowing at the water delivery apparatus, but also that a connection between the control unit 22 and the water delivery apparatus is present. In preferred embodiments, the flow monitor 24 is configured to generate an output signal even when no flow is detected in the pipe 24. In such cases, the control unit 22 also activates the indicator when no water is flowing at the delivery apparatus, but only if the connection between the control unit 22 and the water delivery apparatus is established. This allows the user to determine that the connection between the control unit 22 and the water delivery apparatus is present even when the water delivery apparatus is not in operation.

Allowing the user to so readily determine the status of the connection between the between the control unit 22 and the water delivery apparatus is advantageous because the water delivery apparatus is usually located remotely from the control unit 22, e.g. in a different room or even outside, such that the user cannot simultaneously examine both. Moreover, as is described in more detail hereafter, the preferred embodiment allows an installer to see that a correct connection has been made even before the shower is operational. Conveniently, the indicator 56 is provided on the body of the control unit 22, or on the body of a nearby component of the system.

The indicator 56 preferably comprises a visual indicator, e.g. a lamp or visual display, but may alternatively comprise any other means for providing a user-perceptible indication, e.g. an audio indicator.

Preferably, the indicator 56 is operable in respective modes depending on the signal received at input 46. For example, the indicator 56 may be operable in a first mode (e.g. off) when no signal is received at input 46 and a second mode (e.g. on) when a signal is received at input 46 that is indicative of water flowing at the delivery apparatus. In the preferred embodiment where the signal from the flow monitor 24 is present even when no water is flowing, the indicator is preferably operable in a third mode (e.g. flashing) when the signal received at input 46 is present but indicate that no water is flowing. To this end, the control unit 22 may be configured to determine from the signal at input 46 whether water is flowing or not. This may for example be achieved by determining the frequency of the received signal, or by determining the amplitude of the signal, depending on the operating characteristics of the flow monitor 24.

For example, the flow signal may have a relatively low frequency when no water is flowing. Alternatively, the signal received at input 46 may be used directly or indirectly to operate the indicator 56 such that the state of the indicator is an indication of the state of the signal received at input 46.

For example, the indicator 56 may be off when no signal is received at input 46 and on (constant or intermittent) when the signal is present. The activation of the indicator 56 may be responsive to the frequency of the received signal, or the amplitude of the received signal, so that the user can distinguish between a signal that indicates water flow and a signal that indicates no water flow. For example, the indicator 56 may be activated intermittently at different frequencies depending on the frequency or amplitude of the received signal.

In the preferred embodiment, the indicator 56 comprises a single lamp. In alternative embodiments, the indicator may comprise more than one lamp, or a lamp (e.g. LED) that can adopt more than two colours. In such cases, the control unit 22 may be arranged to illuminate the lamps in different patterns or colours to indicate the respective state of the received signal, or may illuminate a respective one (or more) of the lamps to indicate the respective state of the received signal. For example, a respective lamp may be provided to indicate the respective second and third modes described above.

In the preferred embodiment, when the control unit 22 is connected to the shower (or other apparatus providing a flow signal even when no water is flowing) the single lamp 56 flashes relatively slowly (e.g. once every 4 seconds) when a correct signal connection is made from the shower to the control unit 22. This informs an electrical installer that he has made a correct electrical connection between the shower and pump transformer 22. Typically this is performed prior to the fitting of the pump 18 and before the shower is operational. When water flows at the shower, the lamp 56 flashes relatively quickly (e.g. once every second). Therefore the installer can see if the shower is correctly connected and if it is receiving flow rate data once the shower is turned on.

In other cases, where the control unit 22 is connected to, for example, an apparatus having a flow monitor that only produces a flow signal when water is flowing, the lamp 56 flashes when there is a valid flow signal received, but does not provide the relatively slow rate flash to indicate correct connection.

When power is supplied to the transformer the LED will illuminate when a test button is pressed.

It will be understood that the invention may be used with other water delivery apparatus apart from showers.

The invention is not limited to the embodiment described herein, which may be modified or varied without departing from the scope of the invention.

Claims

CLAIMS: 1. A water delivery system comprising a water delivery apparatus arranged to deliver water into a receptacle; a drainage system connected to said receptacle, said drainage system including a pump; a motor for operating said pump; a power supply for said motor; a control system for controlling the operation of said motor by said power supply; a flow monitor for measuring the flow of water through said water delivery apparatus during use, said flow monitor generating a signal at least when water is flowing through said delivery apparatus, said signal being indicative of the measured flow of water, said flow signal, or a derivative thereof, being communicated to said control system via a communication link, wherein said control system is arranged to activate an indicating device in a first mode in response to receiving said flow signal via said communication link.
2. A system as claimed in claim 1, wherein said flow monitor is configured to generate said signal when no water is flowing through said delivery apparatus, said signal indicating that no water is flowing through said delivery apparatus, said control system being arranged to activate said indicating device in a second mode, different from said first mode, in response to receiving said signal indicating that no water is flowing through said delivery apparatus.
3. A system as claimed in claim 1 or 2, wherein the control system is configured to activate the indicating device in a third mode, different from said first and second modes, in response to determining that no signal is received via said communications link.
4. A system as claimed in any preceding claim, wherein the communications link comprises a wired electrical connection or a wireless link.
5. A system as claimed in any preceding claim, wherein the indicating device comprises at least one visual indicator or a visual display device.
6. A system as claimed in any preceding claim, wherein the indicating device comprises an audio device.
7. A system as claimed in any preceding claim, wherein the indicating device comprises a single lamp which, in said first mode, is caused to flash at a first frequency.
8. A system as claimed in any one of claims 2 to 7, wherein the indicating device comprises a single lamp which, in said second mode, is caused to flash at a second frequency different from said first frequency.
9. A system as claimed in any one of claims 3 to 8, wherein the indicating device comprises a single lamp which, in said third mode, is turned off.
10. A system as claimed in any preceding claim, wherein when water is flowing through said delivery apparatus, the flow monitor is configured to produce a flow signal having a frequency that is indicative of the measured rate of flow of water through said delivery apparatus.
11. A system as claimed in any preceding claim, wherein when no water is flowing through said delivery apparatus, the flow monitor is configured to produce a flow signal having a frequency that is indicative of no water flowing through said water delivery apparatus, preferably a frequency that is lower than any frequency that could be generated in response to a measured rate of flow of water through said delivery apparatus.
12. A system as claimed in claim 11, wherein the indicator device is activated intermittently at a first frequency when the flow signal indicates that no water is flowing, and at a different frequency when the flow signal indicates that water is flowing.
13. A system as claimed in any preceding claim, wherein the indicating device is located at said control system or at said power supply, preferably as part of a housing for said control system or a housing for said power supply.
14. A system as claimed in claim 14, wherein said power supply and said control system are co-located in a common housing, and said indicating device is provided as part of said common housing.
15. A system as claimed in any preceding claim, wherein said water delivery apparatus comprises a shower.
16. A control system for a water delivery system comprising a water delivery apparatus arranged to deliver water into a receptacle; a drainage system connected to said receptacle, said drainage system including a pump; a motor for operating said pump; and a power supply for said motor; a flow monitor for measuring the flow of water through said water delivery apparatus during use, said flow monitor generating a signal at least when water is flowing through said delivery apparatus, said signal being indicative of the measured flow of water, said flow signal, or a derivative thereof, being communicated to said control system via a communication link, the control system comprising means for controlling the operation of said motor by said power supply and being arranged to activate an indicating device in a first mode in response to receiving said flow signal via said communication link.
17. A water delivery system substantially as hereinbefore described and illustrated with reference to the accompanying drawings.
18. A control system substantially as hereinbefore described and illustrated with reference to the accompanying drawings.