Flood Alert! Sump Pump Monitoring System

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1 Flood Alert! Sump Pump Monitoring System Final Design Report Design Team 3 Matt Boston Derek Brooks Aaron ervi Jason Ulbricht Faculty Advisor: Dr. Malik Elbuluk Senior Design Coordinator: Gregory A. Lewis ovember 15, 2012

2 Table of Contents 1. Problem Statement eed Objective Background Marketing Requirements Objective Tree Design Requirements Specification Accepted Technical Design Hardware on-invasive Current Sensors Water Level Sensor LCD and In-Home Speaker Test Button Battery Level Monitoring Hardware Theory of Operation Continuous Water Level Sensor Theory of Operation Hardware Design Modules Software Software Theory of Operation Software Design Modules Software Flow Diagrams Communication Mobile Application Software Mobile Application Theory of Operation Mobile Application Design Modules Power Design Calculations Battery Level Calculations Voltage Divider Calculations Parts List Project Schedules Design Team Information Conclusions and Recommendations References Appendices...55 i

3 List of Figures 1.5.1: Objective Tree : Main Controller Block Diagram (Level 0) : Main Controller Block Diagram (Level 1) : Controller/ Hardware Diagram (Level 2) : Connections to Arduino Mega : on-invasive Current Sensor : Inner Circuit Design of Current Sensor : Ip/Vout Curve of Current Sensor : Pinout of the etape Water Level Sensor : etape Sensor Output : Water Level Sensor Schematic : Water Level Sensor Schematic (Empty) : Water Level Sensor Schematic (Full) : Connection between ATMega2560, LCD, Speaker : Push Button Connection to Arduino : Voltage Divider for Measuring Battery Level : Main System Software (Level 0) : Main System Software (Level 1) : Main System Software (Level 2) : waterlevel() method : powerlevel() method : ison() method : wateralarm() method : poweralarm() method : pumpalarm() method : activatealarm() method : GSM/GPRS Evaluation Board and SM5100B-D : SM5100B-D Block Diagram : Communication UART Serial Connection : Mobile Application Block Diagram (Level 0) : Mobile Application Block Diagram (Level 1) : Communications between Android Device and SQL Server : Software Block Diagram/Flowchart for Mobile Application (Level 2) : Main System Controller Power Supply (Level 1) : Main System Controller Power Supply (Level 2)...44 ii

4 List of Tables 2.1.1: Design Specifications : Key Features of the SM5100B-D : Parts List : Revised Material Cost : Midterm Design Ghant Chart : Implementation Ghant Chart : Datasheet Links...55 iii

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6 Abstract The Flood Alert! system will be a monitoring and alarm system for residential use sump pump systems. The goal is to create a system that will help prevent flooding by alerting the homeowner of critical issues with the sump pump system such as a power outage and the current water level. The system will consist of a water level sensor placed inside the sump pump reservoir and backup power supplies to power the entire system in the event of a power outage. Data from the water level sensor and the power supplies will be relayed to a microcontroller. The microcontroller will process the data to calculate the actual water level and the remaining power levels, and display this to the homeowner via a physical display. An audible alarm placed in the house will alarm the homeowner if a problem occurs. The homeowner will also have access to a mobile application for Android devices which will display water level, power level, and pump status. By providing multiple ways to alert the user of problems and providing them with detailed information regarding their sump pump system, we hope to provide them with valuable time to act on a problematic situation. 1

7 1 Problem Statement 1.1 eed: (By Matt) Many homeowners rely on a sump pump system to remove water from their basements or crawl spaces. When the systems lose power, or equipment fails, flooding can result. If the homeowner is unaware that the system is at risk, they are unable to do anything to help the problem and serious damage can occur. 1.2 Objective: (By Derek) The Flood Alert! Sump Pump Monitoring System will warn the homeowner if there is a power outage to the sump pump and if the water is overflowing. It will also warn the homeowner if the water level is at a critical level even if the system has power. The user will be warned via an alarm placed inside the house, and through the use of a mobile phone application; therefore the user would get the message as soon as a problem arises. The system will also continue to function under backup power when the power goes out. It will keep the user updated with data as the water level and conditions change. This should allow the user time to act to attend to the situation should a problem arise. 1.3 Background: (By Jason) Sump pump alarms are not new to the homeowner market. The new proposed system, however, will separate itself from other systems currently available because there is nothing that will send a wireless signal to a remote device to alert the user that their sump pump is at risk of overflowing. Also, current systems only produce an alarm when the level in the sump pump is getting too high, not in the event of a loss of AC power to the device. An example of a system currently available is described in patent number Said patent describes an alarm unit that mounts near the pump and emits both audible and visual alarms if the water level reaches a specific height. An example of a similar existing system that is aimed towards the industrial rather than home market can be found in the article Design of coal mine underground drainage pump monitoring and controlling system based on PLC and touch screen. The article focuses on the design of an underground drainage pump for a mining environment that uses a control system to monitor it. 2

8 The main thing to be taken from the article is how the workers monitored the water levels in the sump and designed a system that would alert them if water levels reached a critical point. This alarm system is an important part in the design of the pump because it ensures that the sump pump will not flood in the event of a power outage. In order to differentiate this product from other products on the market it will be equipped with a few extra features. As previously mentioned, this will target home users who require the use of a sump pump in their basement or crawl space. For homeowners with sump pumps in their house, power outages can be very scary. If the pump doesn t have power, then there is a chance that water could overflow the sump and flood the basement of the house. This system will attempt to eliminate this hazard in a few different ways. First, the system will alarm the user whenever there is a power outage. During the power outage, the system will rely on a backup battery system to continue functioning. If the sump were to reach a high level during the power outage, the system will detect the high water level and alert the user once again that there is a problem. The main component that will set this product apart from others is that rather than the main unit simply playing an audible alarm from where it is hooked up, this one will also communicate with a mobile application on the homeowner s phone. The mobile application will keep the user updated with current water level readings. It will let the user know if their system has main power, and provide information on the backup power. One problem posed by this design is going to be designing a rechargeable battery that can charge while the system is running off of AC power, and then power the system in the event of a power outage. It is important to properly charge the battery while running off of main power so that it doesn t become overcharged or otherwise ruined. According to the Electrical Engineer s Reference Book; All secondary batteries require a supply of direct current for recharging. The method of charging is important in its effect on battery performance and service life. (29/12) There exist multiple systems in the sump pump market that contain a main pump connected straight to 120VAC, and a smaller backup pump connected to a 12VDC battery. Our monitoring system will utilize one of these currently available systems, but add the features described above. 3

9 1.4 Marketing Requirements: (By Aaron) 1. Easy to install 2. Easy to operate 3. Small 4. Accurate 5. Measure water level 6. Waterproof level sensor 7. Alarm the operator when the water level is high 8. Must know whether or not the sump pump has power 9. Alarm the operator when power fails 10. Full system continues working when power goes out 11. Keep user informed with information via physical alarm and mobile application 1.5 Objective Tree: (By Aaron) The objective of this project is to design a system that will monitor different aspects of an in home sump pump system. Fig shows a block diagram of key objectives for the system based upon our marketing requirements in the previous section. The tree styled diagram takes our marketing requirements and creates branches of related objectives. The numbers in each box correspond to the importance we are placing on that objective out of a unit of one. Our main three objectives are to make the system easy to install, alarm the operator of a power failure, and to alarm the operator of different conditions that might arise with water level, such as a high level, which could result in flooding. 4

10 Sump Pump Overflow Alarm Easy to Install (0.25) Alarm Operator when Power Falls (0.40) Alarm Operator when Water Level is High (0.35) Easy to Operate (0.75) Know if Pump Has Power (0.50) Measure the Water Level (0.50) Small (0.25) System Continues Working When There is o Main Power (0.50) Accurate (0.25) Waterproof Level Sensor (0.25) Continue to Update User With Information Via Physical Alarm and Mobile Application 2 Design Requirements Specification Fig : Objective Tree Table provides a list of the design specifications/engineering requirements that the sump pump alarm system will need to adhere to, in order for it to operate in an in-home environment and satisfy the marketing requirements. The table lists the different engineering requirements along with justifications for the requirements, as well as listing the associated marketing requirements. 5

11 Marketing Requirements Engineering Requirements 1 System must operate off of 120VAC 10 2,11 8,11 4,6 1,2,9,11 7,9,11 9,10,11 7,9,11 4,5,7 1,3 Complete system should last at least 3 hours on backup power Critical system data will be available to user through physical display and mobile application State of charge of backup power will be measured and displayed Water level sensor must be non- corrosive Mobile Application must consist of an easy to use interface and run on a mobile device. Mobile Application will alert user through audible alerts and notifications if a system malfunction, or critical event has occurred System will provide network connection, even during power outage Physical alarm will produce at least 70dB to be heard throughout the home. Water level sensor needs to be accurate to within 3% Water level sensor must be no longer than 3ft in length 6 Justification The system will be powered from a standard home 120V outlet. System needs to continue to function during power outages to keep the area from flooding and to alert the user. The end user should be able to view basic information about the pumps, water level and power level. The user should be able to view the remaining power level of the backup power supply, and the system needs to know how long until complete power outage. The water level sensor needs to last and corrosion could also interfer with accuracy. The user must be able to easily understand and navigate the interface, so as to know if a problem is occuring. The application should get the user's attention to alert them of any problems occuring at the site of their sump pump system The end user needs to continue to be updated with information during a power outage. The user needs to be able to hear the alarm if he/she is in their home. The system needs to obtain accurate level values for calculations. The typical sump pump pump is no longer than 3ft in depth. Marketing Requirements: 1. Easy to install 2. Easy to operate 3. Small 4. Accurate 5. Measure water level 6. Waterproof level sensor 7. Alarm the operator when the water level is high 8. Must know whether or not the sump pump has power 9. Alarm the operator when power fails 10. Full system continues working when power goes out 11. Keep user informed with information via physical alarm and mobile application Table 2.1.1: Design Specifications

12 3 Accepted Technical Design 3.1 Hardware The main controller (shown in Fig ) takes the information from the sump pump system and transfers the desired information to an outside server to be used by a mobile phone application. The controller runs off of 9 volts dc and takes in data from the water level sensor, the power supply, current sensors from the main pump and backup pump, and a current sensor used to determine whether or not the system has power. That information is then uploaded to a server to be sent to the user s phone. It is also sent to an LCD to display the needed information at the actual site where the sump pump is located. The controller will also output an audible alarm when the power goes out or the pump stops running. Water Level Sensor Power Supply Data Main Pump Secondary Pump 9VDC Power Main Controller Data to Server Data to LCD Alarm Speaker Fig : Main System Controller Block Diagram (Level 0) Figures and show the controller broken down into more detail than the level 0 diagram. All of the input data from the sensors will pass through the main hardware block. The hardware block represents an Arduino Mega 2560 as shown in Fig The sensors will all output voltage signals that will provide the status of the water level, the power supply, and the main and secondary pumps. The software on the Arduino Mega will calculate the water level, power supply level, and determine whether or not the pumps are currently operating, and it transfer LCD signals to the LCD display as well as send a data string to the GPRS. This GPRS will then output the data packet to the server. The data packet will include data to be sent to the user such as the level of the water and the remaining life of the backup pump/supply (when main power is out or the main pump is out). 7

13 Main Controller Voltage from Water Level Sensor Power Supply Data LCD Display Primary Pump Secondary Pump Main Power (es/o) Primary Pump Secondary Pump Hardware Water Level Power Supply Ref Voltage GPRS Data Packet To Server LCD Signals 9VDC Power Main Controller Software Data String Alarm Speaker Fig : Main System Controller Block Diagram (Level 1) Figure shows the final level of the system s hardware design. This further detailed diagram shows that the system will be utilizing an SM5100B-D GPRS module, as well as an antenna and SIM card. Further information on these parts can be seen in the communications section. The system will also consist of a test button. This button will allow the user to test the physical speaker alarm. More information on the current sensors, water level sensor and LCD display is provided throughout this section. 8

14 Test Button Water Level Sensor 9V Power Supply User Interface Control Variable Voltage Backup Pump Power Supply Level Voltage 9V Main Power Current Sensor Voltage Primary Pump Current Sensor Voltage Secondary Pump Current Sensor Voltage Data Arduino Mega 2560 ATmega2560 Data SIM Card Alarm Speaker Display Driver GPRS Module SM5100B-D Antenna Controlled Display Output LCD Display Fig : Controller/Hardware (Level 2) Figure shows the pins that the different components indicated in figure will use on the Arduino Mega The component blocks are broken down throughout the paper to show the complete schematics. 9

15 12V Power Adapter (PS) And 9V Battery (BT1) Power Barrel Jack Secondary Pump Battery Level Sensor Main Power (CS1) 5V GD Vin PWM (LS) Test Button (SW1) Primary Pump (CS1) Secondary Pump (CS1) Secondary Pump Battery Level Sensor U1 GPRS Module (U2) LCD (DS) Fig : Connections to Arduino Mega on-invasive Current Sensors (By Matt) In order to fulfill the marketing requirement of knowing whether or not the sump pump system has power and to determine if the sump pump is currently operating, current sensors will be used. A current sensor will be placed on the power cord powering the main controller, as well as the power cord of each pump. The current sensor (Part umber SE from Sparkfun.com) is a non-invasive current sensor that will encircle the wires attaching the devices to their power source. An image of the sensor can be seen below in figure

16 Fig : on-invasive Current Sensor from Sparkfun.com The sensor can handle up to 30 amps which will be plenty as the sump pump uses only amps on start-up. The test circuit for the sensor is shown below in figure is the test circuit found in the datasheet for the current sensor. The current transformer has 2000 turns, and the built in resistance is 10 ohms. I CS k l 10Ω A2 GD Arduino Mega 2560 Fig : Inner Circuit Design of Current Sensor and Connection to Arduino The current sensor will output a voltage proportional to the current that it reads as shown in the graph below from the sensor datasheet. This output voltage will be read from the control board to determine if the board is being powered from the wall or not, thereby determining if there is still 11

17 power from the outlet. For instance, if the current sensed is the 13.3A start-up current, the Arduino will see approximately 65mV based on figure The current sensors attached to the pumps will also relay a voltage back to the controller, in order to determine if either pump is currently operating. Fig : Ip/Vout Curve from SE datasheet Water Level Sensor (By Derek) The water level sensor is a simple sensor that we will be purchasing for our project. As can be seen in Figure , the sensor we are getting acts as a potentiometer that is controlled by the amount of water it is submerged in. The sensor we will be using is called etape and was designed by Milone Technologies. The sensor is 26 inches long, so it fits the constraint of pump reservoir dimensions. Figure shows the top end of the sensor and the 4 pins that are located there. Pins 2 and 3 correspond to the sensor resistance. Pins 1 and 4 can be used as a reference resistance. It will have a voltage that is sent across the sensor from the 5V out on the Arduino board across pins 2 and 3 on the etape sensor. The voltage that is sent to the system will need to be referenced and compared to the voltage that is returned to the board after it goes through the sensor resistance. After the voltages are compared, we can then calculate the water level in the reservoir. 12

18 Fig : Pinout of the etape Water Level Sensor As mentioned above, the etape sensor acts like a potentiometer. The resistance varies depending on the level of water in the tank it is located in. For this sensor, the lower level of water in the reservoir, the higher the resistance outputted. Figure shows a plot of water level vs. resistance. As you can see from the plot, an empty reservoir yields 3000 ohms resistance and a full reservoir (24 to 25 inches) yields around 300 ohms resistance. 13

19 Fig : etape Sensor Output: Water Level vs. Resistance Output from etape Datasheet Figure shows the final schematic of the Milone etape fluid level sensor connected to the Arduino Mega Vw is the voltage supplied by the voltage divider with the variable resistor (Rsense). Vref is the reference voltage supplied by the voltage divider with the reference resistor (Rref). Rref will always be 3Kohms and is built into the resistor by using pins 1 and 4 on the sensor. Rsense will vary between roughly 300 ohms and 3Kohms. R1 and R2 are both 2Kohm resistors, and were chosen to keep the input voltages from exceeding 3.3V and potentially damaging the Arduino. Unity voltage buffers will also be in place to match the impedance of the Arduino. 14

20 5V R2 R1 Vs Vref A0 A1 Arduino Mega GD Rsense WS Rref Fig : Water Level Sensor Schematic Figures and show the results of setting up the water level schematic in pspice. Figure shows how the circuit will respond when the water reservoir is empty and Rsense equals 3Kohms. When this is the case, the output voltage (Vs) should be 3V. Figure shows how the circuit will respond when the water reservoir is full and Rsense equals 300 ohms. When this is the case, the output voltage (Vs) should be 652mV. 15

21 Fig : Water Level Sensor Schematic Empty Fig : Water Level Sensor Schematic Empty 16

22 3.1.3 LCD and In-Home Speaker: (By Jason) For instances when the user is at home, they will be able to view critical system data using a 4 line by 20 character LCD display that will be wired directly to the microcontroller. In addition to displaying important data, the microcontroller will also be wired to a small 8Ω piezoelectric speaker. The speaker will alert the user in the event of a potential flood. Figure below shows how these two components will be wired to the Arduino board. The LCD must be compatible with Hitachi HD44780 display controllers in order to be controlled by the Arduino board. It will be wired in 4-bit mode, meaning only four of the eight data bits will be used, in order to save on the number of digital outputs occupied on the Arduino board. The display will draw power from the 5V source supplied by the microcontroller, and a 10kΩ potentiometer will be wired between the 5V source and ground. The potentiometer will be connected to the Vo pin on the LCD in order to control contrast. Register select (RS), enable (E), and digital bits 4 through 7 (DB4-DB7) will be connected to the digital output pins of the board in order to receive and display the critical data values. Arduino Mega ATmega2560 GD 5V LS (CVS-3108) DIGITAL I/O Rc LED- LED+ DB7 DB6 DB5 DB4 DB3 DB2 DB1 DB0 E R/W RS DS HD-0420E2Z-FSW-GBW Vo VCC VSS Fig : Connection between ATmega2560, LCD Panel and In-Home Speaker 17

23 3.1.4 Test Button (By Aaron) The test button is the main component of the user interface for the main controller. When pressed, it will activate a test alarm and send a signal to the in-home speaker. This is in place to test the overall alarm function of the controller and help make sure it is operating correctly. The push button will act as a switch and send a high signal to a digital pin on the Arduino when it is pushed down and the switch is in the closed position. A pull down resistance of 10K ohms is used to keep the input from floating when the button is not pressed. Fig shows the schematic for the push button. D8 Arduino Mega V SW1 GD R6 = 10K Fig : Push Button Connection to Arduino Battery Level Monitoring In order to measure the remaining level on the backup battery connected to the backup/secondary sump pump, we will use a simple voltage divider connected from the 12V DC battery to the Arduino Mega Figure shows the schematic for this voltage divider. The resistors, R3 and R4, were chosen as 10Kohms and 3Kohms to limit the output voltage to less than 3V. The unity voltage buffer is in place to match impedances. The theory is that as a battery drains, it loses voltage. The Arduino will be programmed to use a hardcoded reference voltage and compare the output voltage from the voltage divider to that reference voltage. From here it will estimate the current percentage value of battery power remaining. 18

24 Backup Pump Battery (12V) BT2 R3 (10K) R4 (3K) + - A5 Arduino Mega 2560 GD Fig : Voltage Divider for Measuring Battery Level Hardware Theory of Operation The controller will act as the intermediary between the user and the sump pump system. The controller will receive information regarding the voltage level of the batteries, the voltage from the water sensor, as well as the main sump pump and the backup sump pump. The controller will take the received information and transmit several items of interest to the user depending on the state of the system. In the event of a system malfunction or a problem (such as high water level), the controller will send a signal to an audible alarm at the local location as well as the mobile location (user s phone). It will also send data to the user s phone regarding the life left on the battery given a loss of main power and a continuous stream of the current water level through GPRS Continuous Water Level Sensor Theory of Operation The continuous water level sensor will monitor the water level inside the sump and output a variable voltage based on the current level of the water. The sensor will have a battery input voltage and will act as a variable potentiometer that is adjusted by the varying water level. The sensor will then output a variable voltage based on the water level directly to the board. The board will then be able to use the sensor voltage along with a reference voltage from the battery to calculate the height of the water level as a usable number. 19

25 3.1.8 Hardware Design Modules The following functionality tables show the details of the inputs, outputs, and functionality of each module in the hardware design of the Flood Alert! Sump Pump Monitoring System. Module Main Controller (Arduino Mega 2560) Designer Matt Boston, Aaron ervi, Derek Brooks Inputs Outputs Functionality Water Level Sensor: Variable voltage (0-3V) Main Power Sensor: Low voltage (Dependent on current) Backup Pump Power Level Sensor: Low volage (Dependent on pump battery level) Primary Pump Current Sensor: Low voltage (Dependent on current) Secondary Pump Current Sensor: Low voltage (Dependent on current) Test Button: Low or High Signal 9V: Power to power the board Speaker: Alarm signal GPRS Module: Data to be sent over network LCD: Data to be displayed on physical display The main board will be powered by 9V DC, and is backed up by a 9V battery. A level sensor is connected to transmit the water level in the sump. The data from the sensor and power inputs will be used to determine system failure and potential flooding. An audible alarm will also sound to alert the user of the failure. The data will be pushed to the mobile application over a cellular network to an outside server. An on board LCD display will also inform the user of water and power levels. Module Designer Inputs Outputs Functionality Main Controller Power Supply Matt Boston,Jason Ulbricht 120VAC to 9VDC Wall Adapter 9V to Controller The power supply will power the main board with 9VDC power. The module will consist of a relay switch, that will switch the system to using the 9V battery as power if a main power outage occurs. 20

26 Module Designer Inputs 5V: Power from Arduino Mega 2560 Outputs Continuous Water Level Sensor Derek Brooks, Aaron ervi Vsense: Voltage (0-3V) indicating water level Vref: Voltage (~3V) to act as reference voltage Functionality The Continuous Water Level Sensor will monitor the water level inside the sump and output a variable voltage that is representative of the current water level to the controller. This will be calculated using Vsense and Vref. Module Designer Inputs Outputs Data packet over cellular network GPRS Module Aaron ervi Data: Data from Arduino through UART Serial Interface 5V: Power from the Arduino to Power the GPRS module Antenna: Quad- band Antenna SIM: SIM card for network access Functionality The GPRS module will function as an intermediary between the main controller and network server. The data will be transferred through the module and out over a cellular network. The module will also consist of a SIM card and antenna. Module Designer Inputs Outputs Functionality Main Power Status Water Level Battery Level Pump Status LCD Display Driver Jason Ulbricht Enable Bit: Enable The LCD Register Select Bit: Select Read or Write Mode DB4- DB7: Data Bits to the LCD The LCD Driver will input the critical system data such as battery charge, water level, and power source and convert the data to be sent to the LCD. Two pins will be used to enable and reset the LCD while four additional pins will transmit critical system data to the LCD. 21

27 Module Designer Inputs Outputs Functionality LCD Display Jason Ulbricht 5V: Power from the Arduino Board RS: Register Select E: Enable Bit Vo: Contrast Control DB4- DB7: Digital Bits for Display Control Visual Display The LCD will be powered using the 5V DC ouput from the Arduino board. It will communicate with the board using 6 digital IO pins. Data from these pins will be displayed on the LCD. A potentiometer will be wired between VSS and VCC to control contrast. Module Designer Inputs Momentary push button User Interface (Test Button) Aaron ervi Outputs Hi- Lo signal to Arduino Mega 2560 Functionality The user interface consists of one momentary push button. The button will act like a switch and if it is pressed down, it will send a Hi signal to the Arduino. The in- home speaker will sound an alarm when pressed. 3.2 Software Figure shows the main software for the monitoring system, which will accept five inputs while handling three outputs. The five inputs will come from four main sources connected to the system. The water level voltage and reference voltage will both come from the water level sensor. The water level voltage will be a variable voltage that is received directly from the sensor and represents the water level in the sump. The reference voltage will come from the power source powering the sensor. The power level voltage will be received from the back-up battery installed with the system. Finally, the operating status for the primary and secondary pumps will come from each pump respectively. These two signals will be used to determine if each pump is running, or if there is a fault that the user must be notified about. The three outputs will all output to different devices on the board. The alarm control will connect to an audio device that will give an audio alert under various conditions. The display driver will connect to an LCD that will give 22

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