Pump controller system and method
A method and apparatus for a pump control system. One or more embodiments of the invention include a pump controller that can perform a self-calibrating procedure, can provide precise motor speed control, can provide a limp mode before shutting down the motor when system parameters are exceeded and/or fault conditions occur, can detect fault conditions, and can store fault conditions for later retrieval.
1. A method of detecting a fault condition in a motor of a pump, the method comprising:
sensing a first bus current value;
sensing a speed of the motor;
incrementing a counter and setting a timer if the first bus current value is greater than a bus current upper limit and if the speed of the motor is greater than or equal to a high speed limit;
attempting to operate the motor in a reverse direction if the counter has been incremented above an increment limit within a first time period;
sensing a second bus current value while the motor is operating in the reverse direction;
operating the motor in the reverse direction for a second time period if the second bus current value is less than the bus current upper limit and attempting to operate the motor in a forward direction once the second time period has elapsed; and
generating a fault condition code and shutting down a drive to the motor if the second bus current value is greater than the bus current upper limit.
2. The method of claim 1 and further comprising incrementing a counter and setting a timer if the first bus current value is greater than about 15 amps and if the speed of the motor is greater than or equal to a high speed limit.
3. The method of claim 1 and further comprising attempting to operate the motor in a reverse direction if the counter has been incremented above five increments within about five minutes.
4. The method of claim 1 and further comprising operating the motor in the reverse direction for about 30 seconds.
5. The method of claim 1 and further comprising indicating to a user that a fault condition code has been generated.