Reduced-pressure treatment systems with reservoir control

1. A method of manufacturing a reduced-pressure system, the method comprising:

providing a power line adapted to be coupled to a power supply;

coupling a reduced-pressure source to the power line, the reduced-pressure source adapted to provide reduced pressure;

coupling a power sensor to a portion of the power line, the power sensor adapted to generate a supply data signal;

providing a pressure sensor adapted to be fluidly coupled to a reservoir, the pressure sensor adapted to generate a pressure signal responsive to a pressure sensed in the reservoir;

providing a reduced-pressure control unit and coupling the reduced-pressure control unit to the power sensor, the pressure sensor, and the reduced-pressure source, the reduced-pressure control unit operable to:

receive the pressure signal,

receive the supply data signal,

generate a control signal in response to the pressure signal and the supply data signal,

correlate the supply data signal to a supply rate of reduced pressure,

determine if a blockage condition exists based on the pressure signal and the supply data signal by comparing the pressure signal to a threshold over a predetermined time while increasing the supply rate to a maximum supply rate, and

communicate the control signal to the reduced-pressure source to terminate the supply of reduced pressure.

2. The method of claim 1 , wherein providing the reduced-pressure control unit further comprises providing a control unit that comprises:

a microprocessor;

a memory device associated with the microprocessor;

a plurality of inputs associated with the microprocessor, the inputs for receiving the pressure signal and the supply data signal and delivering the pressure signal and the supply data signal to the microprocessor in a useable form;

an output associated with the microprocessor, the output for receiving the control signal from the microprocessor and making the control signal available to control the reduced-pressure source; and

wherein the microprocessor and the memory device are operable to determine if an absolute value of a pressure value represented by the pressure signal is greater than the threshold, and if not, to activate the reduced-pressure source, and wherein the microprocessor and the memory device are further operable to stop the reduced-pressure source using the control signal and send an alarm signal when the reduced-pressure source is not able to increase the reduced pressure above the threshold for the predetermined time by increasing the supply rate.

3. The method of claim 1 , the method further comprising coupling the pressure sensor proximate to a top portion of a reservoir.

4. The method of claim 1 , wherein determining if the blockage condition exists comprises determining if the pressure signal decreases below a selected absolute value for a specified time interval and the pressure signal does not rise in absolute value with an increased power supply signal.

5. The method of claim 1 , wherein the blockage condition is at least one of a partial blockage condition or a full blockage condition.

6. The method of claim 5 , wherein at least one of the full blockage condition or the partial blockage condition is a reservoir-full condition.

7. The method of claim 1 , wherein the reduced-pressure source is a vacuum pump.

8. The method of claim 1 , wherein the supply data signal is correlated to current supplied to the reduced-pressure source.

9. The method of claim 1 , wherein the power sensor is a current sensor.

10. The method of claim 1 , further comprising fluidly coupling the reduced-pressure source to an interior space of a reservoir.

11. A method of manufacturing a reduced-pressure system, the method comprising:

coupling a reduced-pressure source to a power line, the power line adapted to be coupled to a power supply;

providing a first sensor adapted to generate a pressure signal;

providing a second sensor adapted to measure a supply signal correlated to a supply rate of the reduced pressure source; and

associating a reduced-pressure control unit with the first sensor, the second sensor, and the reduced-pressure source, the reduced-pressure control unit operable to:

receive the pressure signal from the first sensor,

receive the supply signal from the second sensor,

determine if a blockage condition exists based on the pressure signal and the supply signal, and

turn off the reduced-pressure source if the blockage condition exists.

12. The method of claim 11 , wherein the blockage condition is a reservoir-full condition.

13. A method of manufacturing a reduced-pressure system, the method comprising:

coupling a power line to a reduced-pressure source, the power line adapted to be coupled to a power supply;

coupling a current control unit to the power line;

coupling a power sensor to a portion of the power line between the current control unit and the reduced-pressure source, the power sensor operable to develop a supply signal indicative of a supply rate of reduced pressure to a reservoir; and

coupling a reduced-pressure control unit to the power sensor, a pressure sensor configured to be coupled to the reservoir, and the reduced-pressure source, the reduced-pressure control unit operable to:

generate a first control signal to initiate operation of the reduced-pressure source, identify that a blockage condition exists,

generate a second control signal to further increase the supply rate of the reduced-pressure source based on:

identifying that the blockage condition exists, and

determining that the reduced-pressure source is not able to increase reduced pressure within the reservoir above a threshold for a predetermined time by increasing the supply rate, and

generate a third control signal to terminate the supply of reduced pressure by determining that the reduced-pressure source is not able to increase reduced pressure within the reservoir above a threshold for a predetermined time at a maximum supply rate.

14. The method of claim 13 , wherein the blockage condition is a partial blockage condition.

15. The method of claim 13 , wherein the blockage condition is a full reservoir condition.

16. The method of claim 13 , wherein the supply signal is correlated to power supplied to the reduced-pressure source.

17. The method of claim 13 , wherein the supply signal is correlated to current supplied to the reduced-pressure source.

18. The method of claim 13 , wherein the supply signal is indicative of a valve opening on the reduced-pressure source.

19. The method of claim 13 , further comprising generating an alarm signal if a blockage condition exists.

20. The method of claim 13 , wherein the reduced-pressure control unit is operable to identify that the blockage condition exists based on the supply signal and a pressure signal from the pressure sensor.