BACKGROUND

Submersible well pumps are connected to above-ground drive systems that control the operation of the pump. Some conventional pump controllers include only start capacitors and relays to turn the pump on and off based on system pressure. These pump controllers have limited capabilities with respect to pump control, safety, and customization. Variable frequency drives (VFDs) have also been used to control submersible well pumps but with limited capabilities regarding user-friendly control and customization. Conventional drives have also generally been designed for use with particular types of motors and often cannot be used to retrofit motors that are already installed in the well, especially two-wire, single-phase motors.

SUMMARY

Some embodiments of the invention can provide a controller for a pump driven by a motor, where the pump is in fluid communication with a fluid system. The controller includes a variable frequency drive circuit that controls operation of the pump and a control panel connected to the variable frequency drive circuit. The control panel can include an automatic start button and a stop button. The variable frequency drive circuit can automatically operate in a line fill mode when the pump starts when the automatic start button is engaged and the pump can be disabled when the stop button is engaged.

According to some embodiments, a method of controlling a pump driven by a motor with the pump in fluid communication with a fluid system is provided. The method includes monitoring a pressure in the fluid system, monitoring and adjusting an operating frequency of the motor to maintain the pressure at a pressure set point, and, based on the monitored operating frequency, causing the pump to temporarily boost the pressure in the fluid system to a temporary boost set point for a first time period, where the temporary boost set point is greater than the pressure set point. The method also includes determining whether the temporarily boosted pressure in the fluid system stays above the pressure set point for a second time period and causing the pump to enter a sleep mode when the temporarily boosted pressure stays above the pressure set point through the second time period.

According to some embodiments, a controller for a pump driven by a motor is provided. The controller includes a control panel with a display, directional buttons, and an enter button, and a variable frequency drive circuit that controls operation of the pump. The variable frequency drive circuit is connected to the control panel and is configured to monitor a pressure in the fluid system and monitor and adjust an operating frequency of the motor to maintain the pressure at a pressure set point, where the pressure set point is programmable by a user using the directional buttons and the enter button. The variable frequency drive circuit is also configured to, based on the monitored operating frequency, cause the pump to temporarily boost the pressure in the fluid system to a temporary boost set point for a first time period, where the temporary boost set point is programmable by a user using the directional buttons and the enter button. The variable frequency drive circuit is further configured to determine whether the temporarily boosted pressure in the fluid system stays above the pressure set point for a second time period and cause the pump to enter a sleep mode when the temporarily boosted pressure stays above the pressure set point through the second time period.

